Norma AAR Rodas Eixos

Association of American Railroads
MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION G-II
SAFETY AND OPERATIONS
Published by
The Association of American Railroads
50 F Street, N.W., Washington, D.C. 20001-1564
Copyright Association of American Railroads
Printed in U.S.A.
ISSUE OF 2004
Effective February 1, 2004
Compiled under the direction of the Committees responsible for the subjects shown herein.
(See copyright statement next page)
2/1/04
WHEEL AND AXLE MANUAL
Copyright 2004 by the Association of American Railroads (AAR)
Safety and Operations
50 F Street, N.W.
Washington, D.C. 20001-1564
All rights reserved, including the right to reproduce this book in any
form. It is the AARs intention that this publication be used to pro-
mote the objectives of the AAR and its members for the safe, efficient,
and uniform interchange of rail equipment in North America. To this
end, only excerpts of a rule or specification may be reproduced by the
purchaser for their own use in promoting this objective. No portion of
this publication may be displayed or otherwise made available to
multiple users through any electronic distribution media including
but not limited to a local area network or the Internet. No portion may
be sold or used for advertisement or gain by any entity other than the
AAR and its authorized distributor(s) without written permission from
the AAR.
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AAR Manual of Standards and Recommended Practices
Wheel and Axle Manual
ORDERING INFORMATION
Copies of the various sections of this manual can be obtained as follows:
ORDERS FOR
PUBLICATIONS
Publications Department
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: pubs@ttci.aar.com
Phone: Toll-free 877-999-8824, Direct 719-584-0538
Fax: 719-584-7157
TTCI Web page: www.ttci.aar.com
CIRCULAR
LETTER
SUBSCRIPTIONS
Subscriptions to Circular Letters of the AAR Safety and Operations Technical Services are available in
hardcopy or electronic format (online access via AARs Web page at www.aar.org). Circulars are issued
at least monthly and include industry letter ballots and results, arbitration decisions, notification of rules
and standards revisions, industry early warning and maintenance advisories, and other information related
to mechanical rules and standards. Annual subscriptions commence on July 1 and terminate on June 30
of each year.
For ordering information, contact the following:
Phone: Toll-free 877-999-8824, Direct 719-584-0538
Fax: 719-584-7157
Email: pubs@ttci.aar.com
AAR Web page: www.aar.org
TTCI Web page: www.ttci.aar.com
TECHNICAL
QUESTIONS
For technical questions regarding this manual, contact the following:
Wheels, Axles, Bearings, and Lubrication Department
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: wabl@ttci.aar.com
Phone: 719-584-0670
Fax: 719-585-1895
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TO THE USER
Section G, Part IIWheel and Axle Manual, Manual of Standards and Recommended Practices,
Association of American Railroads (AAR), contains standards and recommended practices for shop
maintenance of wheels and axles.
There are five segments:
1. Mandatory Rules Governing Wheel Shop Practices as Required by Interchange Rules
2. Recommended Wheel Shop Practices
3. General Requirements and Information
4. Figures for Segments 1., 2.0, and 3.0
5. GaugesWheel and Axle Shop
All segments contain editorial changes that increase clarity without changing context. In previous
versions of this manual, revisions and additions were identified by a bold, black, vertical line on the
unbound margin of the page adjacent to the affected change. The date of such revisions and addi-
tions was indicated by the date at the bottom of the page. With this edition, however, change bars
have been omitted. As a result, it is recommended that all segments be reviewed carefully to detect
possible changes.
USERS GUIDE
Section G, Part II, contains three standards and four recommended practices. It consists of the fol-
lowing:
Preface: A listing of the subjects covered in the 25 individual sections, the volumes mak-
ing up this manual. This preface is part of each section.
Table of Contents: A generalized subject listing that indicates applicable standards and
recommended practices.
Table of Contents in Alphabetical Sequence: A listing of the standards (S prefix) and
recommended practices (RP prefix).
Introduction: Explanation of the function of this volume.
Standards and Recommended Practices: The body of this volume deals specifically
with shop maintenance of wheels and axles.
Appendix A: Approved Materials
Appendix B: Revised Page Dates: The status of the pages making up Section G, Part II
with latest revision dates indicated is shown.
RELATED SECTIONS
Section DTrucks and Truck Details
Section D, Part IICode for Designating Design Features for Side Frames and Truck Bol-
sters
Section GWheels and Axles
Section HJournal Bearing and Lubrication
Section H, Part IIRoller Bearing (Shop) Manual
Section JSpecifications for Quality Assurance, M-1003
RESPONSIBILITY
The coverage of Section G, Part IIWheel and Axle Manual, is the responsibility of the AAR
Wheels, Axles, Bearings, and Lubrication Working Committee.
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G-IIiv 2/1/04
PREFACE
The Manual of Standards and Recommended Practices of the Technical Services Division, As-
sociation of American Railroads, is issued by authority of the Management Committee of the Divi-
sion and includes all regularly adopted specifications, standards, and recommended practices of the
Association of American Railroads.
The manual is composed of the following sections:
Section A, Part ITable of Contents, Alphabetical and Numerical Index of Sections A
through N inclusive
Section A, Part IIMiscellaneous Specifications, Standards (010 Series), and Recom-
mended Practices (010 Series)
Section A, Part IIIVacant
Section BCouplers and Freight Car Draft Components (100 Series)
Section CCar ConstructionFundamentals and Details (200 and 2000 Series)
Section C, Part II, Volume 1Specifications for Design, Fabrication, and Construction of
Freight Cars, M-1001
Section C, Part II, Volume 2Appendices M-1001
Section C, Part IIISpecifications for Tank Cars, M-1002
Section DTrucks and Truck Details (300 and 3000 Series)
Section D, Part IICode for Designating Design Features for Side Frames and Truck Bol-
sters (300 and 3000 Series)
Section EBrakes and Brake Equipment (400 and 4000 Series)
Section E, Part IIElectronically Controlled Brake Systems
Section FVacant
Section GWheels and Axles (600 Series)
Section G, Part IIWheel and Axle (Shop) Manual (600 Series)
Section HJournal Bearings and Lubrication (700 Series)
Section H, Part IIRoller Bearing (Shop) Manual (700 Series)
Section H, Part IIILubrication (Shop) Manual (700 Series)
Section IIntermodal Equipment Manual
Section JSpecification for Quality Assurance, M-1003
Section KRailway Electronics
Section K, Part IIRailway Communications
Section LLettering and Marking of Cars (900 Series)
Section MLocomotives and Locomotive Equipment
Section NMulti-Level Manual
Specifications are designated with an M prefix (e.g., M-900). Standards are prefixed S (e.g.,
S-900). Recommended Practices carry the prefix RP( e.g., RP-900). The prefix S or RP will be
followed by a three- or four-digit number. The first digit, 0 through 9, indicates the section in which
the standard or recommended practice can be found, as shown in parentheses above.
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TABLE OF CONTENTS
Subject Standard Page
Rule 1. Mandatory Rules Governing Wheel Shop Practices as Required by
Interchange Rules
S-659 G-II1
Rule 1.1 AxlesGeneral Practices S-659 G-II1
Rule 1.2 AxlesRoller Bearing Practices S-659 G-II2
Rule 1.3 WheelsBoring Mill Practices S-659 G-II5
Rule 1.4 WheelsMounting Press Practices S-659 G-II5
Rule 1.5 Wheel Lathe Practices S-659 G-II9
Rule 1.7 General Practices S-659 G-II10
Rule 1.8 Roller Bearing Mounting and Removal S-723 G-II12
2.0 Recommended Wheel Shop Practices RP-631 G-II17
2.1 Axle Lathe Practices RP-631 G-II17
2.2 Boring Mill Practices RP-631 G-II17
2.3 Wheel Mounting Press Practices RP-631 G-II18
2.4 Wheel Lathe Practices RP-631 G-II20
2.5 Wheel Shop Inspection RP-631 G-II21
2.6 Teardown RP-631 G-II24
2.7 MD-11 Reporting RP-631 G-II24
2.8 Steel Wheel Defects RP-631 G-II33
3.0 General Requirements and Information RP-632 G-II42
3.1 Wheel, Axle, and Bearing Failure Reports RP-632 G-II42
3.2 Handling, Shipment, and Storage of Wheels and Axles RP-632 G-II42
3.3 Wheel and Axle Specifications and Designs RP-632 G-II43
4.0 Figures for Segments 1., 2.0, and 3.0 RP-633 G-II46
5.0 GaugesWheel and Axle Shop RP-634 G-II117
Appendix A. Approved Materials S-727 G-II148
Appendix B. Revised Page Dates G-II149
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G-IIvi 2/1/04
TABLE OF CONTENTS IN
ALPHABETICAL SEQUENCE
Subject Standard Page
Approved Materials S-727 G-II148
Axle Lathe Practices RP-631 G-II17
AxlesGeneral Practices S-659 G-II1
AxlesRoller Bearing Practices S-659 G-II2
Boring Mill Practices RP-631 G-II17
Figures for Segments 1., 2.0, and 3.0 RP-633 G-II46
GaugesWheel and Axle Shop RP-634 G-II117
General Practices S-659 G-II10
General Requirements and Information RP-632 G-II42
Handling, Shipment, and Storage of Wheels and Axles RP-632 G-II42
Mandatory Rules Governing Wheel Shop Practices as Required by
Interchange Rules
S-659 G-II1
MD-11 Reporting RP-631 G-II24
Recommended Wheel Shop Practices RP-631 G-II17
Roller Bearing Mounting and Removal S-723 G-II12
Steel Wheel Defects RP-631 G-II33
Teardown RP-631 G-II24
Wheel and Axle Specifications and Designs RP-632 G-II43
Wheel Lathe Practices S-659 G-II9
Wheel Lathe Practices RP-631 G-II20
Wheel Mounting Press Practices RP-631 G-II18
Wheel Shop Inspection RP-631 G-II21
Wheel, Axle, and Bearing Failure Reports RP-632 G-II42
WheelsBoring Mill Practices S-659 G-II5
WheelsMounting Press Practices S-659 G-II5
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TABLE OF CONTENTS IN
NUMERICAL SEQUENCE
Standard Subject Page
RP-631 Recommended Wheel Shop Practices G-II17
RP-632 General Requirements and Information G-II42
RP-633 Figures for Segments 1., 2.0, and 3.0 G-II46
RP-634 GaugesWheel and Axle Shop G-II117
S-659 Mandatory Rules Governing Wheel Shop Practices as Required by
Interchange Rules
G-II1
S-723 Mandatory Rules Governing Wheel Shop Practices as Required by
Interchange Rules (continued)
G-II12
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2/1/04 G-IIix
Wheels and Axles
INTRODUCTION
Wheel and axle work and roller bearing mounting are among the most important functions per-
formed by the Mechanical Departments on North American railroads. The purchase of wheels and
axles and the labor to machine, assemble, and maintain them require very large annual expendi-
tures. About one and one quarter million new wheels are purchased and mounted each year, and a
larger number of roller bearings are mounted along with new and secondhand wheels. These expen-
ditures justify special efforts to establish good workmanship and to maintain the best practices that
are currently available.
This manual has been prepared for employees who are responsible for in-shop wheel and axle work
and its on-line inspection and for roller bearing mounting. It is essential that they have a thorough
understanding of their work, and detailed study of this manual will aid them very much. It is de-
sirable for any employe having anything to do with wheel and axle work and roller bearing mount-
ing to have a general knowledge of the subjects in this manual even though the employees duties
may not involve all phases of the subject.
It also is to be expected that each railroad wheel manufacturer delivering mounted wheelsets, loco-
motive builder, or car manufacturing company will provide itself with the necessary gauges for its
own protection and will make spot checks, and any additional checks, that may be deemed neces-
sary to ensure proper fit of all truck components.
The wheel manufacturer, the locomotive builder or car builder, and the railroad shops or subcon-
tractors shall be responsible for the following:
Mounting of wheels
Mounting of bearings
Quality control program as to workmanship entering into the above steps
The purpose of this manual is to cover the best available practices in the field. There are methods
of performing certain classes of work other than those described, but the experience of many has
been assembled and is here made available to all.
AAR requirements and recommended practices for roller bearing repair shops are covered in the
AAR Manual of Standards and Recommended Practices, Section H-II, Roller Bearing Manual.
This Wheel and Axle Manual, the AAR Manual of Standards and Recommended Practices, and the
Field Manual of the AAR Interchange Rules are revised periodically. Frequent reference should be made
to each.
All approved freight and Amtrak passenger car wheel and axle shops, bearing mounting shops, and
bearing reconditioning shops are listed in Circular Letters that include the identifying marks to be
used in wheel mounting stamping and roller bearing marking. Each of these shops will be inspected
periodically in accordance with the general procedures established by the Field Manual of the AAR
Interchange Rules, Rule 120, Section A. Work done by shops that are not APPROVED is not ac-
ceptable in interchange service and is not considered as correct repairs for car repair billing. Lo-
comotive shops and passenger car shops, other than Amtrak, are listed for information only and are
neither inspected nor approved.
Requests for approval of wheel and axle shops and roller bearing mounting shops must be directed
to the Technical Services Division, Association of American Railroads, 50 F Street, NW, Washing-
ton, DC 20001, and must include the location of the facility and the name of the railroad or compa-
ny. This request should include a statement that the shop facility has been made ready for
inspection and is capable of meeting the minimum AAR requirements, in accordance with the
Wheel and Axle Manual.
In addition to the foregoing, all wheel and axle shops and roller bearing mounting shops must meet
the requirements of the AAR Manual of Standards and Recommended Practices, Section J, Quality
Assurance Specification (M-1003).
The shop also must be capable of demonstrating the ability to meet AAR requirements in a reason-
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G-IIx 2/1/04
Wheels and Axles
able length of time, such as an 8-hour period for a complete wheel shop operation and a 4-hour pe-
riod for a partial wheel shop operation or for roller bearing mounting.
All nonmembers must remit a check for the amount shown in the Office Manual of the AAR Interchange
Rules, Rule 120, payable to the Association of American Railroads, prior to the inspection to defray
the expense for each inspection. Shops failing to qualify for certification will be assessed an addi-
tional amount for each visit until certification is granted. Approved shops shall be inspected peri-
odically by the AAR Field Operations Group, and failure to perform work in accordance with this
Wheel and Axle Manual would be justification for removal from the approved list until specific
conditions or violations are corrected.
Segment 1., Mandatory Rules Governing Wheel Shop Practices as Required by Interchange
Rules, has been adopted as standard, is made mandatory by the Field Manual of the AAR Inter-
change Rules 36, 41, and 43, and must be followed. Where reference is made in the mandatory seg-
ment to paragraphs in the recommended practice segment, any dimensions or tolerances given as
recommended practice become mandatory, but the method of accomplishing this may vary provided
that the intended end result is achieved.
Segments 2.0 to 4.0, inclusive, of this manual are to be considered as recommended practices.
Segment 5.0 contains gauges, some of which are Standard.
Drawings of a wheel and an axle are shown in Fig. 1 with the various parts identified. Fig. 2 shows
a drawing for Amtrak passenger car inboard bearing axles. This nomenclature should be used to
describe these various parts.
Most gauge figures in paragraph 4.0 are for purpose of illustration only and are not working draw-
ings unless so indicated. Refer to working drawings in paragraph 5.0 for tolerances on dimensions.
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Wheels and Axles
Nomenclature for wheels and axles
Fig. 1
FRONT BACK
BORE
BACK HUB FILLET
BACK RIM FILLET
FLANGE
BACK FACE OF RIM
HUB
FRONT HUB FILLET
PLATE OR WEB
TREAD
FRONT FACE OF RIM
THROAT OF FLANGE
CL
E D C B A
Roller Bearing Raised Wheel Seat Axle
A = Tapered end
B = Journal
C = Dust guard seat
D = Wheel seat
E = Body
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Wheels and Axles
Inboard bearing axlesAmtrak passenger cars
Fig. 2
H
AXLE
INBOARD ROLLER BEARING
(DISC BRAKE SEAT)
AXLE
INBOARD ROLLER BEARING
(DRIVE DEVICE SEAT)
H
A C D E F G F D C B A B
A = Wheel seat started
B = Wheel seat
C = Journal
D = Speed sensor gear seat
E = Disc brake seat
F = Body
G = Drive device seat
H = Rolled relief grooves
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SEGMENT 1. S-659
RULE 1. MANDATORY RULES GOVERNING WHEEL SHOP PRACTICES AS
REQUIRED BY INTERCHANGE RULES
RULE 1.1 AXLESGENERAL PRACTICES
Rule 1.1.1 Axles must meet the specified machine tolerances within this manual. When specified
machine tolerances cannot be maintained, lathes must be adjusted or repaired.
Rule 1.1.2 New and converted axles (as defined in paragraph 2.1.2.5) must conform to dimen-
sions and specifications as shown in this manual (see Figs. 4.1, 4.2, 4.3, 4.8, 4.9, 4.12, and 4.13).
Secondhand axles must conform to dimensions and specifications as shown in this manual (see
Figs. 4.4, 4.5, 4.7, 4.11, 4.12, and 4.13).
Rule 1.1.3 If an axle is stenciled OverheatedScrap or if the journal surface or end of axle has
any discoloration due to overheating (light straw, dark straw, or any departure from the normal
bright finish) or if circumferential checks or cracks are found in the journal, the axle must be
scrapped. The journal must be mutilated or the axle suitably marked to prevent reuse.
When roller bearings are removed from axles marked RB Overheated, the axle must be
inspected, and if found to be overheated, the journal must be mutilated or the axle suitably
marked to prevent reuse.
Rule 1.1.4 Centering holes in the ends of axles must form an angle of 60 and be in accordance
with Fig. 4.8. Any burrs around centers must be removed. Centering holes must be wiped clean
before placing the axle in the lathe in order that journals and wheel seats will not be eccentric and
grit will not cut the lathe centers.
Rule 1.1.5 Files may be used only to break sharp edges of dust guard seats and ends of axles and
to work down upset ends or surface defects of roller bearing axles, providing the bearing seat
diameters are not reduced below minimum and the surface roughness meets specifications. Files
must not be used on fillets or wheel seats.
Rule 1.1.6 Wheel seats of secondhand axles need not be re-turned prior to mounting, provided
they meet specifications of Rules 1.1.2 and 1.1.7. Wheel seats requiring correcting may be machine
cut, ground, rolled, or polished with abrasive cloth (80 grit or finer). Any depression, circumferen-
tial scores or checks, damage, injury, longitudinal channel way, or crack in the wheel seats must be
removed. To ensure true entry of the axle into the wheel bore, a taper must be turned on the outer
end of the wheel seat starting at least 1/32 in. less than the wheel seat diameter and extending a
maximum of 1/2 in.
Rule 1.1.7 At the beginning of each shift, from each lathe in service, an axle wheel seat must be
checked at not less than three points in its length and on two different diameters at each of these
points to ensure rotundity. Measurements shall be taken a minimum of 1 in. from the wheel seat
outboard edge, at the center, and 1 in. from the wheel seat inboard edge. The variation for any two
of these measurements must not exceed 0.002 in. As the wheel seat is measured from the journal
end to the axle center, at no point should the dimension decrease. Outside micrometer calipers
must be used for measuring axle wheel seats.
Rule 1.1.8 Machined and secondhand wheel seats and journal portions of unmounted second-
hand axles in freight car service and the entire length of unmounted secondhand axles in other
services must be magnetic particle tested by the wet method before remounting.
A detectability test must be performed weekly and a record kept (see example in Fig. 4.71). The
test consists of inspecting a test axle with a known circumferential crack of at least 1 in. long or an
equipment manufacturers approved test piece that will indicate and verify the following:
Proper brilliance of ultraviolet light
Proper concentration of bath solutions (see Fig. 4.14)
Proper magnetic power source and operation of equipment
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SEGMENT 1. S-659
See paragraph 2.5.3 for recommended wet method inspection procedures. Alternate procedures are
acceptable providing they receive AAR approval.
Note: The test axle or test piece must be thoroughly cleaned of the last test indicators before test-
ing. This must be verified by light before the test is started.
Rule 1.1.9 Axles having drive devices or brake discs mounted on the body of the axle between
wheel seats must have the body of the axle magnetic particle tested by the wet method when such
wheel assemblies are processed through the wheel shop for driving device attention (see
paragraph 2.5.3). It is not necessary to remove the brake discs or drive devices before testing.
Rule 1.1.10 Welding on axles is not permitted, and any axle showing welding or cutting torch
damage is scrap. Only electrochemical metal deposition processes, covered in Rule 1.2.7, are
approved repair techniques.
Rule 1.1.11 Any nicks, gouges, or deep scratches less than 1/8 in. deep, as measured from the
original body contour, must be ground out to a smooth contour blended into the contour of the axle
body. Axle bodies may be machined providing surface defects can be removed without going below
specifications. Any axle body that has been machined must be magnetic particle tested by the wet
method after machined and be completely free of defects before application. Avoid placing nicks,
punch marks, chisel marks, or stamping, etc., in the bodies of axles, including axles having
as-forged bodies.
Rule 1.1.12 When axle markings consisting of the manufacturers brand, date, serial number,
heat number, and grade of axle (U, D, F, etc.) will be obliterated due to refinishing, a record of this
information shall be made and the marking restored after refinishing by cold stamping
1/4-in.-high figures as shown in Fig. 4.9.
Rule 1.1.13 Shops that finish machine new axles must mark these axles in accordance with
Fig. 4.9, Note 13.
RULE 1.2 AXLESROLLER BEARING PRACTICES
(Reference Figs. 4.4, 4.5, 4.7, 4.11, 5.12, 5.18, 5.19, and 5.24)
Rule 1.2.1 Maximum allowable run-out between the axle wheel seat and journal is 0.015 in. total
dial indicator reading (see Fig. 4.4). When run-out exceeds this, axle wheel seats must be turned or
centers corrected to bring the axle wheel seat and journal run-out within this tolerance.
Rule 1.2.2 Unmounted secondhand axles and any mounted axles involved in a major derailment
must be checked on centers or by the alternate method, as shown in Fig. 4.11, for bent condition
using a dial indicator on each journal and obtaining a reading near the end of the journal and near
the journal fillet. If the total dial indicator reading between the end and fillet on either journal dif-
fers more than 0.010 in. in one complete revolution, the axle must be scrapped. The journal must
be mutilated or the axle suitably marked to prevent reuse.
Rule 1.2.3 Roller bearing axles with mounted wheels that have been in derailment must be
checked for bent condition with roller bearings removed. This check, including tolerances, must be
the same as specified in Rule 1.2.2.
RULE 1.2.4 Cleaning
Before attempting to qualify axles, the axle ends, journals, journal fillets, dust guard seats, and
wear ring grooves must be thoroughly cleaned.
Abrasive method may be used provided it is 80 grit or finer.
Fillets with fretting that cannot be removed with abrasive cloth may be refinished by
grinding or machine cutting, providing the U dimension is not reduced below minimum
length as checked with the gauge shown in Fig. 5.24.
Indications of fretting checks on the periphery of the journal fillet within 3/8 in. of the dust
guard seat need not be removed as long as the filet is in compliance with Fig. 4.7.
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SEGMENT 1. S-659
RULE 1.2.5 Inspection and Repair
Journals must be carefully inspected in accordance with Fig. 4.5 each time a roller bearing is
removed to determine whether the journal is within prescribed tolerances.
There shall be no abrupt changes or steps over the length of the journal. Defects shall be
smoothly blended (1/8-in. radius or more) into the contour of the journal surface by filing,
sanding, or roll burnishing such that there are no high spots and depressions are no more
than 1/16 in. deep. Journal finish measured at the interference fit surface must not exceed
63 microinch.
Depressions are allowed in cone seating areas only if the following additional requirements
are met:
The average cone seat diameter is at least .0001 in. above the minimum.
Depressions spanning an entire cone seat must not exceed 1/8 in. wide at the points of
intersection with the cone seating boundaries.
The combined area of all depressions in each cone seat must not exceed 1 in.
2
(see
Fig. 4.6).
Rule 1.2.8 gives the accept/reject criteria and process for repairing grooves in journals
caused by inboard seal wear rings.
Note: Depressions blended in this manner need not be considered when determining average jour-
nal diameter or journal variance.
Cone seats, wear ring grooves, areas where upsets occur, and tapered ends must comply with the
requirements in Fig. 4.5; all other areas shall average no more than .005 in. smaller than the min-
imum cone seat diameter.
Gauges used to measure journal diameter must be the digital or dial indicator type with 0.0001-in.
graduations. Journal diameter gauges must be referenced to a Class X or better standard. Temper-
ature differences, if any, between the reference standard and the journal being measured must be
compensated for.
Cone seat diameter as shown in Fig. 4.5 and located with the roller bearing seat location gauge
shown in Fig. 5.18 shall not vary more than .0015 in.
Rule 1.2.6 gives the criteria for using the electrochemical metal deposition process to repair axles
that are not in compliance with Fig. 4.5.
Rule 1.2.6 For new axles being machined, for axles being converted to a smaller size, or for
reclaiming axles with defective cap screw holes, see paragraph 2.1.2.5. Suitable jigs, fixtures, or
machines must be used to correctly locate and guide the drill or drills when drilling cap screw
holes in the ends of an axle. Taps should be sharp to ensure good threads. Clean holes after tap-
ping. Check hole location using the gauge shown in Fig. 5.12 and check threads with a standard
thread gauge.
Rule 1.2.7 All roller bearing axle journals and dust guards that are undersize or secondhand
axle journals that are long or have a groove caused by the inboard seal wear ring may be repaired
by an electrochemical metal deposition process providing they meet the following requirements:
1.2.7.1 Journals must be no smaller than 0.004-in. diameter under minimum.
1.2.7.2 The seal wear ring groove on a journal must not be more than 0.010 in. deep. Grooves
greater than 0.002 in., but not to exceed 0.010 in., must be restored to their existing diameter.
(Reference Fig. 4.5 for allowable secondhand axle diameter specifications.)
1.2.7.3 Repaired journals must meet the requirements in Rule 1.2.4 and in the AAR Manual of
Standards and Recommended Practices, Section G, Specification M-967. Surface roughness must
not exceed 63 microinch.
1.2.7.4 For plating area limits, see Fig. 5.18.
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SEGMENT 1. S-659
1.2.7.5 Repaired axles must be stamped at one end of the axle with a letter V followed by one or
two sequential numbers, identifying symbol, and repair date month and year (See Fig. 4.9, Note 11
and Note 12.) A record of the axle stamping, in sequence of manufacturer, month and year, grade,
heat number, serial number, and electrochemical deposition solution batch number, must be main-
tained by the facility.
1.2.7.6 Buildup of the roller bearing axle journal or dust guard by electrochemical metal deposit
shall be performed only in facilities that have been certified according to the controlling MSRP
Section G, Specification M-967, and only by operators certified according to Specification M-967.
1.2.7.7 Under no circumstances shall an axle that shows signs of overheating or discoloration due
to an overheated bearing be repaired by the electrochemical metal deposition process. Any circum-
ferential steps or grooves encompassing the entire circumference of the axle journal in the bearing
seat area greater than 0.001 in. deep are a sign of a loose cone and their presence is considered an
overheated axle. Axles that have severe water etch more than 50% of the area of a bearing seat
may not be restored. Water etch less than 50% of the circumference may be restored.
1.2.7.8 The full length of the journal must be restored to the base of the journal radius. Restora-
tion of the entire journal is required on all repairs except those requiring only a seal wear ring
groove repair.
1.2.7.9 Dust guards must be no smaller than 0.004 in. under minimum. When, and only when,
fitted backing rings are applied to axles with toleranced H dimensions with the intent of produc-
ing a fitted application, the dust guards must be measured in a similar manner to axle journals as
described in Rule 1.2.4. Surface roughness shall not exceed 125 microinch. For plating area limits,
see Fig. 5.19.
Rule 1.2.8 Axles with grooved journals caused by inboard seal wear rings may be returned to
service provided there are no abrupt changes or sharp edges after repair. The following provisions
must also be met:
Groove averages no more than 0.002 in. deep and does not exceed 0.004 in. deep at any
point; or
Groove does not exceed 0.010 in. at any point and axle is used in conjunction with the AAR
Conditionally Approved or Approved parts listed in Table 1.1; or
Groove is repaired in accordance with Rule 1.2.7.
Notes:
1.2.8.1 Groove depth must be measured using a gauge with minimum resolution of 0.0001 in. and
a probe small enough to fit completely into the groove without interfering with the groove walls.
1.2.8.2 Average groove depth shall be determined by averaging no fewer than three equidistant
points.
Table 1.1 Components approved for use with inboard seal wear ring groove
Size
Manufacturer 5 1/2 in. 10 in. 6 in. 11 in. 6 1/2 in. 12 in. 7 in. 12 in.
Timken seal
Timken sleeve
K151172
K152373
K150471
K150491
K147750
K149549
K150189
K150483
Brenco seal wear ring with polymer insert 1106D 1206D 1306D
Timken Axle Saver seal wear ring K153392 K151590 K153391
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SEGMENT 1. S-659
RULE 1.3 WHEELSBORING MILL PRACTICES
(Reference Figs. 4.15, 4.16, 4.17, and 4.19)
Rule 1.3.1 Wheel bores must meet specified tolerances within this manual. When specified toler-
ances cannot be maintained, the boring mill must be corrected.
Rule 1.3.2 Chuck jaws must be properly aligned radially and vertically. The bearing points of the
chuck jaws must be maintained within a tolerance of 0.015-in. total dial indicator reading to a
plane at right angles to the axis of the boring bar; and within a tolerance of 0.008-in. total dial
indicator reading of being concentric with the boring bar (see Fig. 4.15). Test wheels or other suit-
able means must be available to test boring mills for radial and plane error. See paragraph 2.2.2
for an alternate method for checking wheel bores. Shops using boring mills with independent
chuck jaws must use the alternate method.
Rule 1.3.3 A sufficient number of wheel bores must be checked at not less than three points in
the wheels length and on two different diameters at each of these points to ensure rotundity and
consistent accuracy in bore diameter. The variation of any two of these measurements must not
exceed 0.002 in. If any taper does exist, the smaller diameter must be at the outside end of the hub
bore.
Rule 1.3.4 The wheel bore must be sufficiently smaller than the wheel seat diameter to enable
the required mounting pressure to be obtained as set forth in Fig. 4.19. Generally, a fit allowance
of 0.001 in. per inch of wheel seat diameter will result in the required pressure.
Rule 1.3.5 The wheel must be properly aligned in position on the mill with regard to concentric-
ity and to plane. Two or more separate cuts, one or more roughing and one finishing, must be made
in boring new steel wheels. If more than 1/4-in. thickness is to be removed, two roughing cuts must
be taken. The finishing cut should be approximately 1/64 in. thick. If separate roughing and finish-
ing cutters are carried simultaneously on the boring bar, they must be separated by a distance
greater than the length of the wheel hub being bored. A 1/8-in. radius or a 1/8-in. to 3/8-in. chamfer
must be provided at the entry or back of the hub of all wheels after the finishing cut (see Fig. 4.17).
Rule 1.3.6 Secondhand wheels or dismounted misfit wheels may be remounted without reboring
providing wheel bores meet all of the specified tolerances within this manual.
RULE 1.4 WHEELSMOUNTING PRESS PRACTICES
(Reference Figs. 4.18, 4.19, 4.20, and 4.22 through 4.35)
Rule 1.4.1 Wheel mounting presses must be equipped with a dial pressure gauge and a pressure
recording gauge. These gauges must be used for every mounting operation and must agree within
2%. The dial gauge must be checked by means of a dead weight tester or accurate master gauge
at least once in each 6 months of service. Records must be attached to or kept in close proximity to
the gauge, showing the date last tested and the date actually put into service. The recording gauge
must have a minimum resolution of 100 tons per inch with graduations superimposed on the chart
in no larger than 5-ton increments. It must make a complete wheel fit pressure diagram of each
wheel mounted as shown in Figs. 4.22 through 4.29.
1.4.1.1 The diagram of each wheel shall be marked to show the identifying wheel number. The
nominal wheel seat diameter shall also be marked as shown in Fig. 4.20.
1.4.1.2 Mounting pressure must be applied at the wheel hub. If the final wheel mounting pres-
sure is not within the limits shown in Fig. 4.19 or the diagram is not acceptable as described below
and in Figs. 4.22 through 4.29, the mounting chart and corresponding wheel must be plainly
marked MISFIT.
1.4.1.3 The intent of the wheel mounting diagram is to provide a record indicating whether or not
the wheel bores and seats meet all AAR requirements when mounted. The area under the mount-
ing curve represents the amount of energy required to press the wheel onto the axle. The shape of
the curve indicates whether that energy is the result of interference fit or some other source of fric-
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SEGMENT 1. S-659
tion (false tonnage). If the interference fit is adequate, taper is correct, lubrication is proper, align-
ment is true, and wheel and axle finishes are compatible, tonnage will increase smoothly and
almost linearly from the beginning to the end of the mount at a slightly decreasing rate. This will
yield maximum area under the curve. The following accept/reject criteria apply:
1.4.1.3.1 Mounting diagrams that are within 2 ton of the limits shown in Fig. 4.19 must be ideal
mounts as shown in Fig. 4.22.
1.4.1.3.2 Mounting diagrams must continue to build tonnage at least until the wheel is 75% on.
Minor anomalies prior to this that may be caused by system fluctuations are acceptable provided
they do not exceed 2 ton.
1.4.1.3.3 A drop-off at the end of the mount (after 75% of the mount is complete) is acceptable
provided the tonnage after the drop-off exceeds the minimum tonnage shown in Fig. 4.19.
1.4.1.3.4 The entry spike at the beginning of the mount must not exceed 30 ton or three times
the tonnage after the drop-off, whichever is less. For example, if the spike is no greater than 30 ton
and the tonnage after the drop-off is no less than 10 ton, the mount is acceptable.
1.4.1.3.5 Pounding (also known as hammering, hunching, or slip stick) is allowed at the end of
the mount provided that the tonnage at the low end of the pound exceeds minimum tonnage shown
in Fig. 4.19 and the wheels are centered and still in gauge. This condition is a product of incompat-
ible surface finish between the wheel bore and axle seat and must not be allowed to persist. Once it
is identified, it must be located and resolved.
1.4.1.3.6 Mounting diagrams that reach required tonnage only as the result of a quick tonnage
buildup (usually during the last half of the mount) as shown in Fig. 4.28 are unacceptable. They
normally indicate a mechanical obstruction or an excessive positive taper of the wheel seat and/or
wheel bore. Note that the tonnage would have only reached 56 ton except for the undesirable con-
dition.
1.4.1.4 Misfits must be demounted and recorded in a log showing the misfit date, demounting
date, serial number of both wheels, and their disposition. Wheel mounting diagrams and misfit
logs must be kept on record for 5 years. Misfit wheels shall be demounted immediately or placed in
a designated holding area for demounting at a later time.
Rule 1.4.2 In mounting and demounting wheels, where damage could occur to the journals, both
journals of the axle must be protected during the entire operation to prevent nicking and scratch-
ing the journal surfaces and a suitable method must be used to prevent upset ends and high spots
on roller bearing journals.
Rule 1.4.3 The wheel seats and bores must be cleaned carefully to remove rust, grit, chips, and
grease. Both wheel seat and bore must be coated as necessary with an AAR-approved mounting
lubricant (see Appendix A on page G-II148) or with a mixture of basic carbonate white lead and
boiled (not raw) linseed oil, with boiled linseed oil only, or with caster oil. The entire bore and one
half of the wheel seat should be coated, including entry radius or taper. Once the mounting proce-
dure has begun, lubricant may not be removed or further applied. To avoid scoring of the mounting
surfaces, it is particularly important that the starting edges of the wheel seat and wheel bore be
thoroughly coated with the material used. If a mixture of white lead and boiled linseed oil is used,
the proportion should be 12 lb of white lead paste to 1 gal of boiled linseed oil, thoroughly mixed,
which will give a gravity of 58 to 62 Baume at 60 F to 80 F. Only a sufficient quantity for a few
days operation should be prepared due to the drying quality of the boiled linseed oil. A thicker
lubricant tends to reduce the pressure and cause misfits that would otherwise be correctly
mounted. Lubricant should be mixed at least 12 hours before using to give it the proper blend.
Ready-mixed white lead compound, as specified above, may be purchased. It should be stirred
before applying. If boiled linseed oil is used alone, the oil must meet the requirements of
ANSI/ASTM D-260, Type I, Standard Specification for Boiled Linseed Oil. Dirt, and grit should
be kept out of the lubricant and the brush with which it is applied. If castor oil is used, the oil must
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SEGMENT 1. S-659
meet the requirements of ASTM D-960, Standard Specification for Raw Castor Oil. Do not use
raw linseed oil or lubricating oils either alone or for thinning.
Rule 1.4.4 Wheels must be mounted centrally with respect to the center of the axle within
mounting tolerances of 3/32 in. using wheel centering and mounting gauges in accordance with
specifications in this manual. With automated equipment, accuracy of centering of wheels on axles
shall be checked every tenth pair.
Rule 1.4.5 After wheels are mounted, they must be checked with a suitable mounting check
gauge at three equidistant points on the circumference, at a distance of 1 1/4 in. down from the
apex of the flange, to determine whether or not they are mounted within limits. With automated
equipment, every tenth pair must be checked. If measurement at any check point indicates that
wheels are not within limits, the wheel spacing must be adjusted to bring wheels within such lim-
its (see Figs. 4.29 through 4.33). Alternatively, if the gauge is correct at one place on the wheel set
and the radial and plane error is within specification, the wheel set is suitable for service. If radial
and plane error is not within specification, then wheels must be dismounted and the wheel bore
corrected. If the spacing cannot be adjusted within limits, the wheels must be dismounted and the
axle should be checked for bent condition and the wheel bores for out-of-plane.
Rule 1.4.6 New wheels mounted on the same axle must be the same tape size and bear the same
tape size marking. Secondhand wheels should be within one tape number in circumference as
measured with a standard wheel tape. Care must be taken to secure the greatest service life from
the metal in both wheel seat and hub bore.
Rule 1.4.7 In the selection of wheels for mating and in the machining and mounting of wheels
and axles for interchange service, the following must be observed. (See the Field Manual of the AAR
Interchange Rules, Rule 41, for additional restrictions).
1.4.7.1 New wheels must not be mated with secondhand wheels.
1.4.7.2 Wheels that are mounted on the same axle must meet the same AAR design criteria (i.e.,
the following attributes must match):
1.4.7.2.1 Manufacturer: See paragraph 3.3.7 (Note: Amtrak wheels may be of different manufac-
turers.)
1.4.7.2.2 Design designation: (e.g., CH-36, CJ-33, etc.) See Fig. 4.18.
1.4.7.2.3 Class of heat treatment: (e.g., U,A, B, C, L, etc.) See paragraph 3.3.6.
1.4.7.2.4 Plate shape: (Note: Mounting of straight plate wheels is prohibited.)
1.4.7.2.5 Tread profile: (Note: AAR-1B profile is mandatory on new or reprofiled wheels.)
1.4.7.2.6 Tape size: (Must be the same tape for new wheels and within one tape for reprofiled
wheels.)
1.4.7.3 If, for any reason, it is necessary to dismount from an axle one wheel of a pair of mounted
wheels, the mate must also be dismounted regardless of condition, and the axle must be handled
as a secondhand unmounted axle. This does not apply to wheels that are misfitted in mounting
operations, since only the misfit wheel needs to be removed in such cases.
1.4.7.4 The following wheels must not be returned to service:
1.4.7.4.1 Cast iron wheels
1.4.7.4.2 Davis cast steel wheels
1.4.7.4.3 Wrought steel wheels dated prior to January 1, 1927
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SEGMENT 1. S-659
1.4.7.4.4 Wrought steel wheels having rims measuring 1 in. or less along with any of the follow-
ing:
Dated prior to January 1, 1939
No manufactured date markings
Illegible manufactured date markings
1.4.7.4.5 Wrought steel wheels that can be identified as being manufactured by ARMCO
1.4.7.4.6 Wrought steel, one-wear, 28-in. wheels with any of the following:
Of B-28, D-28, or Y-14 design as indicated by markings on wheels
No design markings
Illegible design markings
1.4.7.4.7 Cast steel wheels marked AAR X-2 or AAR X-4
1.4.7.4.8 Abex cast wheels marked SOUTHERN in raised letters on the back of the wheel plate
along with any of the following:
Dated prior to May 7, 1958
One-wear, 50-ton, with less than 1/4-in. flat back face of rim and dated May 7, 1958 to Sep-
tember 8, 1960
One-wear, 70-ton, marked 70T and dated May 7, 1958 to January 1, 1964
One-wear, 70-ton, marked CJ-33 and U1 or 70T and U1 and dated January 1, 1964
through December 31, 1969
1.4.7.4.9 Griffin cast-steel, 33-in., three-riser wheels with either of the following:
One-wear, 70-ton, ball rim design, marked AAR X-3 or AAR CS
Two-wear, marked AAR X-5 or AAR CS-2 and dated 1960 to 1963
1.4.7.4.10 Straight plate wheels, except A-28 and A-30
1.4.7.4.11 Straight-plate wheels with missing or illegible manufacturer identification
1.4.7.4.12 Valdunes, Creusot-Lorrie non-heat-treated, 36-in., straight-plate wheels marked F or
FW manufactured in 1980 and 1981
1.4.7.5 Do not mount 28-in. wheels on axles that have been converted from 6 1/2 in. 12 in. to
6 in. 11 in. journals unless the axle has been fully machined along its entire length to nominal
6 in. 11 in. axle dimensions.
1.4.7.6 The mounting or remounting of straight plate wheels to freight equipment used in inter-
change service is prohibited.
Rule 1.4.8 Wheels and axles should be at approximately the same temperature when mounted.
Any wheel that has been heated to aid in demounting must not be remounted.
Rule 1.4.9 A wheel must not be remounted if evidence of overheating from being in a fire is
present. A wheel having any evidence of welding or a wheel having holes in the plate must not be
remounted.
Rule 1.4.10 In handling pairs of mounted wheels, wheel sticks, chains, or hoods that catch the
axles on the journal surfaces or on roller bearings must not be used.
Rule 1.4.11 The wheel shop mark and mounting date (month and two-digit year) shall be cold
stamped on the outside hub face of one wheel of each wheel set. The latest stamping will indicate
the last shop where the wheel was mounted. Heights of characters shall be not less than 5/32 in.
and not more than 5/16 in. Stamping shall be arranged on a circular arc or straight line, and the
outer edge of the hub must not be intersected by any of the stamped characters. The wheel shop
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SEGMENT 1. S-659
symbol shall consist of not more than four characters to identify the railroad, car owner, contract
shop, or car builder and not more than two additional characters to identify the particular shop
doing the work (see Fig. 4.34 for method of stamping).
Rule 1.4.12 Treads of each wheel of mounted wheel sets must be concentric with journal surfaces
within 0.030 in. total dial indicator reading, and flange throats of each wheel must be in plane
within 0.060 in. total dial indicator reading. Both readings must be measured as shown in
Fig. 4.35.
Rule 1.4.13 Alternate methods for measuring, collecting, displaying, and saving data, other than
those specifically outlined in this manual, must be approved by the AAR and a copy of the
approval must be maintained at the facility using the equipment. The measuring devices must be
calibrated against a known standard such as an electrical shunt calibration. This should be per-
formed at the beginning of each shift. If other calibration methods are provided by the manufac-
turer of the measuring devices, they should be performed as specified.
RULE 1.5 WHEEL LATHE PRACTICES
(Reference Figs. 4.35 through 4.52)
Rule 1.5.1 To qualify for reapplication to service without recontouring, all secondhand freight car
wheels must meet specifications of the Field Manual of the AAR Interchange Rules, Rule 41. Wheels
not meeting specifications that have sufficient service metal may be recontoured providing they
meet all specifications of this manual and the Field Manual of the AAR Interchange Rules, Rule 41,
after recontouring. When wheel lathes are not capable of producing wheels to these specifications,
lathes must be corrected.
Rule 1.5.2 Wheel tread and flange contours must be in accordance with Figs. 4.36 or 4.37, as
applicable, and measured with gauges shown in paragraph 5.0 (See also Figs. 4.43 through 4.52)
or other AAR-approved alternate standard.)
Rule 1.5.3 Freight car wheels must be checked for back-to-back measurement before contouring,
at a distance 1 1/4 in. down from the apex of the flange, to determine correct flange thickness.
After recontouring, wheels with over 53 3/32-in. back-to-back measurement should have flange
thickness of 1 5/32 in. (0 on AAR steel gauge NF finger). Wheels with 52 15/16 in. to 53 3/32 in.
must have flange thicknesses of 1 5/32 in. to 1 3/8 in., but both flanges of a pair must not vary
more than 2/16 in. Wheels with less than 52 15/16 in. or more than 53 3/16 in. back-to-back mea-
surement are out of gauge and should not be contoured. (Note: Passenger car wheels must be
53 3/32 in. to 53 3/8 in. and must always be machined to 1 5/32 in. +1/16 in. and 0 in. flange thick-
ness.) See Figs. 4.36, 4.37, and the Field Manual of the AAR Interchange Rules, Rule 41.E.9, for flange
thickness tolerances. See Fig. 5.27, Wheel back-to-back service limit gauge (typical).
Rule 1.5.4 To qualify for reapplication, recontoured wheels must have a flange thickness of
1 5/32 in. minimum to 1 3/8 in. maximum, and flange thicknesses on a wheel set must not vary
more than 2/16 in. Both wheels of a pair should be within one tape number in circumference.
Treads must be concentric with journal surfaces within 0.030 in. total dial indicator reading; and
flange throats in plane, at right angle to axis of axle, within 0.045 in. total dial indicator reading
when measured as shown in Fig. 4.35. Wheel tread and flange contours must be in accordance
with this manual (with exception, that the radius on the outside edge of the rim may be 3/8 in.)
unless wheel rims are reduced in thickness to such an extent that lathe drive dogs interfere with
the machining of the radius, in which case the radius may be reduced as necessary or a chamfer
used. Wheel surfaces must be machined using a cutting tool with no less than 5/32 in. nose radius.
Feed marks must not exceed 1/8 in. wide at any place on the wheel tread or flange contour.
Rule 1.5.5 New or reconditioned bearings must be applied any time a wheel set is processed
through a wheel shop, including shops with wheel-truing machine operations. (Exception: passen-
ger car wheel sets with inboard bearings and not removed from car.)
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SEGMENT 1. S-659
Rule 1.5.6 In addition, an H shall also be paint stencilled on the front plate at least 1 in. high on
those wheels of curved-plate, heat-treated configuration that have yet to be stencilled or when the
stencilling has become illegible.
Rule 1.5.7 Recontoured wheels must be ultrasonically tested after turning in accordance with
paragraph 2.9, Ultrasonic Inspection of Reprofiled Wheels, to qualify for reapplication to inter-
change service.
RULE 1.6 STANDARD GAUGES
Rule 1.6.1 Wheel and axle shops must have gauges as shown in paragraph 5.0 or a suitable
method to verify specified tolerances as shown in this manual.
Rule 1.6.2 Gauges must be maintained within specified wear tolerances. When gauges are found
to be defective, they must be removed from service.
RULE 1.7 GENERAL PRACTICES
Rule 1.7.1 Machinery in continuous operation must be checked at least once each week and
machinery not in continuous operation must be checked at least once each month in accordance
with this manual to ensure that specified tolerances of this manual are met. A record must be kept
of inspections showing the date, condition of the machine, nature of the correction, if any is
required, and signature of inspector. When machinery is removed from service for any reason, the
machinery inspection report must show Out of Service and the reason for removal. Machinery
reentering service must be inspected at time of reentry. A copy of inspections must be on record at
wheel shops for at least 2 years. See the example in Fig. 4.71.
Rule 1.7.2 Wet method magnetic particle testing equipment must be checked in accordance with
this manual and a record kept in the wheel shop for 2 years. See Fig. 4.71 for the recommended
form to be used; Fig. 4.14 for the recommended method of checking bath solutions; and
paragraph 2.5.3 for recommended machinery specifications. The original certification of the centri-
fuge tube must be maintained for the life of the tube.
Rule 1.7.3 New or secondhand axles must not be coated between the wheel seats with heavy
asphaltic, tar, or cement-base coatings that prevent detection of flaws by ordinary inspection. If
axles are coated, only light-bodied materials may be used.
Rule 1.7.4 Journals and dust guards of all axles with wheels mounted must be completely coated
with a rust preventive that will provide proper protection and that can be readily removed. This
applies to wheels just mounted and to mounted wheels in storage and in transit for application.
Rule 1.7.5 Wheel sets must be arranged when stored so the wheel flanges cannot strike either
the roller bearing housing, the axle journal, or the body of the adjacent axle. Fig. 4.74 illustrates a
track arrangement for wheel and axle assemblies having roller bearings. When this arrangement
is not available, assemblies should be stored one behind the other on single tracks.
Rule 1.7.6 The same precautions must be used in placing mounted wheels on a car for shipment.
In addition, they shall be securely blocked to prevent rolling and end-sliding. Details of approved
methods are given in the current issue of the AAR Open Top Loading Rules Manual.
Rule 1.7.7 Mounted wheel and axle assemblies removed from cars for reasons other than con-
demnable defects, such as those removed from dismantled cars, must be carefully inspected before
they are placed in stock to determine if they are suitable for reuse. Any wheel and axle assembly
that does not meet the acceptable requirements of the Field Manual of the AAR Interchange Rules
must be handled in accordance with the requirements of this manual.
Rule 1.7.8 Building up slid-flat spots of worn flanges of wheels by welding, welding fractures, or
burning or drilling holes in the plate is prohibited.
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SEGMENT 1. S-659
Rule 1.7.9 Wheels with less than 52 15/16-in. or more than 53 3/16-in. back-to-back measure-
ment are out of gauge and must not be returned to service (see Figs. 4.29 through 4.33). See
Fig. 5.27, Wheel back-to-back service limit gauge (typical).
Rule 1.7.10 The wheel shop mark and mounting date (month and two-digit year) shall be cold-
stamped on the outside hub face of one wheel set. The latest stamping will indicate the shop where
wheel was last mounted. Heights of characters shall be not less than 5/32 in. and not more than
5/16 in. Stamping shall be arranged on a circular arc or straight line, and the outer edge of the hub
must not be intersected by any of the stamped characters. The wheel shop symbol shall consist of
not more than four characters to identify the railroad, car owner, contract shop, or car builder and
not more than two additional characters to identify the particular shop doing the work (see
Fig. 4.34 for method of stamping). See the latest AAR Circular Letter for a listing of wheel shop
reporting works and shop locations.
Rule 1.7.11 The removing railroad is responsible for ensuring that each wheel set removed for
Why Made Codes 50, 51, 95, or 96 is inspected to determine the cause of overheating. Each active
bearing manufacturer and the last bearing reconditioner must be invited to participate in the
inspection. A form MD-11 must be completed and forwarded to the AAR Technical Services Divi-
sion for all confirmed inspection, teardown, and report. This procedure is designed to ensure con-
sistent, accurate, and orderly MD-11 reporting.
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SEGMENT 1. S-723
RULE 1.
RULE 1.8 ROLLER BEARING MOUNTING AND REMOVAL
RULE 1.8.1 Bearing Removal
1.8.1.1 Bearing assemblies with journal housings should be removed according to the manufac-
turers specifications. No general instructions can adequately cover the various types.
1.8.1.2 Bearing assemblies with rotating end caps must be removed as follows:
1.8.1.2.1 Remove cap screws and the scrap locking plate.
1.8.1.2.2 Remove the end cap.
1.8.1.2.3 Remove the entire bearing assembly from the axle (see Fig. 4.61).
RULE 1.8.2 Bearing Mounting
1.8.2.1 Before proceeding with bearing application, the wheels, axle, and roller bearing assem-
blies must be approximately the same temperature. Bearings with the same certificate number,
disregarding suffix letter, must be mounted on the same axle. For example, AAR No. 6 and 6A
bearing may be mounted on the same axle. Exception: AAR No. 10 and 10A must not be mounted
on the same axle. Housing-type bearing pairs must be of the same type and manufacturer. Roller
bearings must be protected during mounting against contamination from dirt, sand, water, etc.
Caution: There are two designs of 7-in. freight car roller bearings and two designs of 7-in. freight
car roller bearing axles in service. The journal length dimension on a 7-in. freight car axle governs
which one of the two 7-in. freight car roller bearing designs must be mounted on that axle. The
mounting of 7-in. freight car roller bearings is governed by Fig. 4.75.
1.8.2.2 The axle journal, journal fillet, and dust guard seat must be cleaned with a wire brush or
other suitable means. Journal diameters on new, secondhand, or reclaimed axles must be checked
for proper size, and journal ends must be checked for upset condition (Fig. 4.5). A dial or digital
snap gauge (with 0.0001 scale) must be used to measure the journal diameter and must be cali-
brated using the master disc (at least Class X tolerance) that is the same temperature as the axle
being measured unless appropriate compensation is made for the temperature difference between
the master disc and the journal being measured. Check for proper fillet with a fillet gauge
(Fig. 4.7) to ensure proper seating of the backing ring. Excessive galling or fretting of the fillet will
require scrapping or reworking the axle, in accordance with established dimensional allowances.
Axle ends must be clean and free of dirt and contaminants. Visually inspect tapped holes in the
axle ends for thread damage, dirt, and corrosion.
1.8.2.3 Roller bearing assemblies may be installed with a bearing press or wheel press or with
portable fixtures.
1.8.2.4 A pilot sleeve (Fig. 4.62) or telescoping pilot sleeve and mounting sleeve (Fig. 4.63) must
be used to guide the bearing assembly on the axle, ensuring correct alignment of parts and protec-
tion to seals. An improperly aligned press or worn tooling can cause distortion of bearing compo-
nents and/or damage to the journal. When an unpiloted assembly sleeve is used, bolts should not
be torqued up but should be left loose so the sleeve can align itself when the bearing is being
mounted on or removed from the axle journal.
1.8.2.5 Coat the bearing seats of the axle with castor oil, heavy mineral oil (SAE4O or SAE5O
mineral oil), or a molybdenum disulphide and oil mixture before mounting bearings. Do not use
white lead. Lead compounds may be detrimental to lubricating greases by acting as an oxidation
catalyst. Mounting lubricants must be kept free of contaminants.
1.8.2.6 Apply a moderate to heavy uniform coating of an approved lead-free rust preventive (see
Appendix A on page G-II148) to the journal fillet portion and adjacent dust guard area of the axle
prior to mounting the bearing on the axle. After the bearing has been mounted and the cap screws
torqued, if the proper amount of rust preventive material has been applied to the axle fillet, a seal-
2/1/04
2/1/04 G-II13
SEGMENT 1. S-723
ing bead should form at the juncture of the backing ring and the axle. If no sealing bead is formed,
apply a brush coat around the dust guard seat at the backing ring juncture.
1.8.2.7 Apply the bearing to the axle. Mounting pressure must be applied directly to the inner
ring or seal wear rings. Caution should be exercised in order not to apply pressure on the outer
ring, seals, or other parts of the bearing because damage will result. Caution should be exercised
that seals are not damaged and that seal wear ring does not slip out of place. Do not insert any tool
or instrument between the seal element and the seal wear ring because damage to the seal lip may
result.
1.8.2.8 Press the bearing in place using the proper mounting sleeve (Fig. 4.62) or telescoping pilot
and mounting sleeve (Fig. 4.63). Seating pressures (Fig. 4.64) must be used to ensure that the
backing ring is properly in contact with the journal fillet. Bearing or wheel presses used for mount-
ing roller bearings on axles must be equipped with relief valves so that a specified pressure can be
maintained for a short interval to ensure that the bearings are properly seated (rather than to
obtain the required pressure reading on the dial pressure gauge during the surge of the press
when the backing ring of the bearing contacts the axle fillet). The pressure relief valves must oper-
ate when the dial pressure gauge indicates the specified pressure. The dial pressure gauge must
read in tons and be checked by means of a dead weight tester, or an accurate master gauge, at
least once in each 6 months of service. A tag must be securely attached to the gauge showing the
date last tested and the date actually put into service. The seating pressure chart should be posted
at the pressing area.
RULE 1.8.3 Applying End Cap
1.8.3.1 New or secondhand end caps and new or secondhand cap screws can be intermixed with
new or reconditioned bearing assemblies.
Apply the end cap, cap screws, and a new locking plate to the end of the axle. End caps must be of
the same manufacturer and AAR approval number as the bearing being applied (Exception: see
Rule 1.8.6.2 concerning the interchangeability of end caps for certain bearings by certificate num-
ber and by size.) End caps must not have a lubricant fitting. See Fig. 4.66 for cap screw sizes and
torques. (Note: See Fig. 4.65 for Amtrak passenger car end cap application.)
1.8.3.2 Run up the cap screws to less than prescribed values. Finish tightening the cap screws
using a click-type torque wrench with a slow, steady, even force being applied to obtain the pre-
scribed AAR torque values. The cap screws must be retorqued in sequence until no further move-
ment of the cap screws results from the application of the specified torque. An AAR chart showing
torques must be posted (Fig. 4.66). Torque wrenches should be checked frequently (preferably
daily) to ensure correct readings and must be checked at least weekly with a record kept of the
checks. In order to check the torque of cap screws when defective roller bearings are inspected at
the shops, it will be necessary to maintain a dial or digital-type torque wrench at each bearing
shop.
Torquing devices other than click-type wrenches must be approved by the AAR and a copy of the
approval maintained in the facility using the equipment. If the approved device can be calibrated
against a known standard, this should be done at the beginning of each shift or at the appropriate
period as stated in the letter approving use of the device.
Torque wrenches must be permanently marked with a serial number for identification on the
weekly record of checks.
RULE 1.8.4 Checking Bearing Mounted Lateral
1.8.4.1 Tapered roller bearings must have mounted lateral play checked and must meet manufac-
turers tolerances (See Fig. 4.69). These tolerances must be posted in roller bearing mounting
shops.
If the bearing rotates freely when rotated by hand but does not indicate 0.001 in. on the dial indi-
cator, the application is satisfactory for service. Check mounted lateral with a magnetic-base dial
indicator as shown in Fig. 4.68. Force the bearing laterally toward the wheel hub, and zero the
2/1/04
G-II14 2/1/04
SEGMENT 1. S-723
indicator. Then pull the bearing laterally away from the wheel hub to obtain a lateral reading. The
use of metal bars to force the bearing laterally to obtain lateral readings is prohibited.
1.8.4.2 Reconditioned or new bearings must not exceed manufacturers mounted lateral limits.
Whenever mounted lateral is more or less than allowed tolerances, the roller bearing should be
removed and corrections made.
1.8.4.3 Lock cap screws by bending all tabs of the locking plate flat against the sides of the cap
screw (Fig. 4.67).
RULE 1.8.5 Identification
1.8.5.1 For identification, each mounted roller bearing will be marked by a suitable means
(sticker, stencil, etc.) on the outer ring in 1 1/2-in. or larger letters, as follows:
1.8.5.2 Locking plates shall be stamped or legibly etched with the following information. The
minimum character size shall be 1/8 in. (0.125 in. or 3 mm). If the characters are pin punched, the
punch marks must overlap.
Note: See latest AAR Circular Letter for a listing of wheel shop reporting marks and shop loca-
tions.
In instances where end caps and locking plates are removed only, all of the information from the
old locking plate shall be transferred onto the new locking plate. In addition, the company marks
of the shop removing and reapplying the end cap shall be applied along with the date of replace-
ment (mm/yy) and the letters EC (end cap removal only) (see Fig. 4.77).
Note: To ensure that the original mounting shop maintains accountability for journal size and
condition, end cap removal information should be applied in addition to, rather than in place of,
mounting shop information. The letters EC serve to prevent confusion in the field as to what
information represents original bearing mounting and what information represents end cap
removal only.
RULE 1.8.6 Interchangeable Parts
1.8.6.1 Cap screws (except for AAR-20 bearings) and cap screw locking plates are interchange-
able on all bearings.
1.8.6.2 Only end caps for Classes D-, E-, and F-size bearings with the part numbers listed below
may be interchanged. If the end cap applied is not of the same manufacturer and approval number
as the bearing to which applied, a distinctively colored locking plate will be used to identify the
bearings. If, for any reason, a colored locking plate is removed without also removing the bearing,
it must be replaced with one of the same color to maintain bearing identity. Devices that are to be
attached to standard locking plates and that are intended to be used in place of colored locking
plates for identification must be approved by the AAR.
N = New roller bearings
R = Reconditioned roller bearings
Note: Not applicable to Amtrak passenger car bearings
N = If new, and (mm/yy) month and year of bearing manufacture (same as stamped on the
outside of the cup) and company and shop identification marks of mounting shop
OR
R = If reconditioned, and (mm/yy) month and year of bearing reconditioning and company
and shop identification marks of reconditioning shop
AND
Company and shop identification marks of mounting shop if different from recondition shop
2/1/04
2/1/04 G-II15
SEGMENT 1. S-723
RULE 1.8.7 Storage of Reconditioned Bearings
1.8.7.1 If bearing assemblies are to be placed in stock, they must be stored in proper packaging,
covered, and stored in a dry area free from dirt and moisture.
RULE 1.8.8 Removal and Reapplication of Roller Bearing End Caps
1.8.8.1 Shops that desire to remove and reapply roller bearing end caps for any reason, but are
not currently certified as an AAR-approved roller bearing mounting facility, must request and
receive specific AAR approval under 9A status. These requirements do not apply to wheel truing
operations for passenger cars (Amtrak, transit, or private business cars) or motive power. To
request such approval, an application must be made to the AAR, c/o Chief, Technical Standards,
Transportation Technology Center, Inc., P.O. Box 11130, 55500 DOT Road, Pueblo, CO 81001. The
following information must be provided:
1.8.8.1.1 A detailed procedure that will be employed to ensure compliance with those parts of the
specification applicable to the removal and reapplication of the roller bearing end cap. Include the
following steps as a minimum:
1.8.8.1.1.1 Remove the wheel set completely from the truck side frames (i.e., the bearing must
not be under load).
1.8.8.1.1.2 Clean the exterior of the bearing to permit adequate visual inspection of all external
parts. Do not use solvents or chemicals that may damage the seal elastomer.
1.8.8.1.1.3 Inspect for the following in accordance with the Field Manual of the AAR Interchange
Rules, Rule 36:
External parts visibly cracked, broken, or bent
Loose, cocked or damaged seals
Loose backing rings
Internal defective parts
Table 1.2 Interchangeable end cap part numbers
Company
Bearing
Certificate No. Color
Class D
5 1/2 10
Class E
6 11
Class F
6 1/2 12
Class G
7 12
Timken 1, 1A Orange K85521
K526743
K523744
K151329
K85510
K523745
K523746
K529703
K529702
K85517
K523747
K523748
K523706
K151307
K529705
K95199
K147768
K523749
K523750
Brenco 5, 5A Green D1011
1011
1000
E1111
1111
1100
F1211
1211
1200
G1311
1311
1300
Hyatt 6, 6A Blue 4-R-3810 4-R-3811
4-R-3812
4-R-3813
4-R-3813-14
4-R-3885
4-R-3888
FAG 13 Red 120987/2 120988/7 120989/7
Koyo 14 White 703N60
120360
704N60
120460
705N60
120560
706N60
120660
NTN 19 Purple RT20D11
RT20D31
RT20E11
RT20E31
RT20F11
RT20F31
SKF 23 Yellow 1637503-11 1637504-11 1637505-11

FAG 26 Brown 120987/14 120988/14 120989/14
2/1/04
G-II16 2/1/04
SEGMENT 1. S-723
1.8.8.1.1.4 If secondhand cap screws are to be reused, do the following:
Visually check the threads and washer face on the underside of the cap screw head for
damage.
Check the cap screw body for stretching or bent condition using the gauge shown in the
AAR Manual of Standards and Recommended Practices, Section H, Part II, Fig. 3.18.
Lubricate the cap screw threads and washer face prior to application with either AAR
M-942 journal roller bearing grease, AAR M-963 journal box lubricating oil, or an equiva-
lent lubricant that does not promote flash rusting.
1.8.8.1.1.5 Transfer all existing locking plate information to a new locking plate in accord with
Rule 1.8.5.2.
1.8.8.1.1.6 Apply end caps in accordance with Rules 1.8.3.1 through 1.8.4.3. Mounted lateral
greater than 0.025 in. after end cap replacement is an indication of excessive internal wear and is
cause for rejection.
1.8.8.1.2 Identification of all facilities removing and reapplying end caps in accordance with
AAR-approved procedures. Existing or proposed company marks (maximum four letters) and code
letters/numbers indicating the facility location or extension abbreviation (minimum two charac-
ters and maximum four characters) should accompany each application for AAR approval.
1.8.8.1.3 A description of all requisite equipment that will be used and training of personnel that
will be accomplished, to ensure compliance with the specifications and required procedures.
Subsequent to review of the submitted application with supplemental attachments, an on-site
inspection may be performed by the Field Operations Group before approval is granted.
2/1/04
2/1/04 G-II17
SEGMENT 2.0 RP-631
2.0 RECOMMENDED WHEEL SHOP PRACTICES
2.1 Axle Lathe Practices
2.1.1 An effective, continuous contact between the axle wheel seat surface and the wheel bore
surface is essential to ensure a secure and permanent wheel fit.
2.1.2 The following axle conversions are permissible:
2.1.2.1 A plain bearing raised wheel seat axle may be converted to a roller bearing raised wheel
seat axle by machining the journal, dust guard seat, and wheel seat provided the requirements as
shown in this manual are met.
2.1.2.2 A plain or roller bearing raised wheel seat axle may be converted to a smaller size raised
wheel seat roller bearing axle provided the resulting axle meets the journal, dust guard seat, and
wheel seat dimension requirements for the size produced.
2.1.2.3 When a roller bearing axle is converted to a smaller size, new end cap screw holes must be
provided, in accordance with Rule 1.2.6. For axles being converted or for reclaiming axles with
defective cap screws, new cap screw holes must be provided, located at angular spacing midway
between existing end cap screw holes and of proper sizes and screw circle diameter for the size axle
produced. Plug existing hole with the appropriate size cap screw of sufficient length or a cap screw
in combination with a suitable metal plug to ensure that the screw seats in the bottom of the hole
and prevents the screw head from seating on the end of the axle. Tighten cap screws to 100 ftlb
over the maximum specified in Fig. 4.66 for that size and cut off flush with the end of the axle.
2.1.2.4 When a plain bearing axle is converted to a roller bearing axle of the same size, the dust
guard to wheel seat fillet radius may be reduced to 3/4 in. while maintaining all other dimensions
in accordance with specifications as shown in this manual.
2.1.2.5 Converted axles must be marked in accordance with Fig. 4.9, Note 10.
2.1.2.6 When converting an axle to the next smaller size roller bearing axle, the dust guard seats
will be toleranced, if required, for new RWS axles of the size to which converted (see Fig. 4.2).
2.2 Boring Mill Practices
2.2.1 Boring the wheel is a very important operation in wheel and axle shop practice. If the bore
is not perpendicular to the plane of the wheel, the wheel will not run true, causing uneven flange
wear that may result in damage to track and equipment. If the bore is not concentric with the
tread, the resulting eccentric wheel will cause damage to track, equipment, and lading. If the sur-
face of the finish bore is not true, smooth, and of the proper diameter, it may tear the axle wheel
seat during mounting or have insufficient grip of the wheel seat, which may lead to an axle failure
or a loose wheel.
2.2.2 To check for wheel hub bore concentricity and taper, one of two methods may be used. One
method consists of attaching a dial indicator or gauge having 0.001-in. readout increments to the
boring bar for use in conjunction with a true test wheel chucked in the boring mill to be checked.
The test wheel must have dimensionally true flange, flange throat radius, and standard tapered
tread surfaces with true horizontal and vertical reference surfaces machined on the inside diame-
ter of the back rim face. See Fig. 4.15 for a method of checking concentricity of the wheel bore with
a maximum total dial indicator run-out (TDIR) of 0.008 in. permissible and a method of checking
bore taper with a maximum TDIR of 0.015 in. permissible. A test wheel of each diameter bored in
production will be used for periodic checking in accordance with specifications in this manual. The
alternative method for checking wheel hub bore concentricity and taper consists of swinging
mounted wheel sets in a lathe or on a fixture supporting the journal surfaces. A dial indicator will
be employed at the wheel treads to determine concentricity with journal surfaces, and a TDIR of
0.030 in. will be permissible. Wheel flange throats must be in plane at right angles to axis of axle.
Checking must be performed on the first mounted wheel set of each diameter bored in production
2/1/04
G-II18 2/1/04
SEGMENT 2.0 RP-631
each shift but not less frequently than the periodic checking required in accordance with this man-
ual. Either method will satisfy the requirements of this manual to verify boring mill integrity and
condition. Irregularities exceeding prescribed tolerances must be corrected immediately. Fig. 4.16
indicates a satisfactory method for grinding boring mill chuck jaws. A true concentric disc is
chucked in a low position to hold the jaws in their normal operating position during the grinding
operation. An adjustable grinder is secured to the boring bar to perform the necessary jaw face
grinding.
2.2.3 With the boring mill itself accurately aligned, it is next necessary to align the wheel prop-
erly in position on the mill with regard to concentricity and to plane. The tread of the wheel must
be clean in order to permit concentric chucking and boring. Wheels having new tread and flange
contours will normally be aligned automatically with contact of the jaws. Worn wheels should be
aligned from the back face of the rim by means of shims under the contact points of the jaws. Steel
wheels that have the front face of the rim machined should be aligned by means of hard steel
blocks of equal height resting on the cleaned surface of the table and supporting the front face of
the rim of the wheel. This alignment should be checked in any case to ensure the required accu-
racy of the finished bore.
2.2.4 Axles with oversized wheel seats up to 1/8 in. greater in diameter than standard may be
used with wheels bored oversize. Wheels can be bored out for use on larger axles provided the load
capacity, maximum finish bore, and minimum hub wall thickness are not exceeded as per the AAR
Manual of Standards and Recommended Practices, Section G, Specifications M-107 or M-208.
2.2.5 In mating two worn or re-turned multiple-wear or two-wear steel wheels, it is preferable,
for economy in handling, to have the rim thickness of each approximately the same. If continued in
service, they will reach the condemning limit for rim thickness at the same time. This practice
should be followed except in emergencies.
2.3 Wheel Mounting Press Practices
2.3.1 The quality of the wheel mounting operation is dependent upon the skill and care with
which the axle lathe and boring mill operations are performed. However, good workmanship on
wheels and axles would be lost if the mounting operation were not performed properly. The wheel
seat and bore must not be damaged during the mounting operation. The wheels must be mounted
centrally on the axle and at the proper gauge distance. The following paragraphs in this section
describe recommended practices that should be employed to accomplish the desired results.
2.3.2 A soft block should be used on all roller bearing axles when wheels and inner races are
being mounted or dismounted. The use of the block will minimize upset ends and high spots on the
axle caused by uneven pressure applied to the ends of the axle. The end of the press ram, mount-
ing press sleeves, anvil block, and all auxiliary contacting parts should be maintained in good con-
dition to ensure that all surfaces involved contribute to the correct alignment for wheel press
operations.
2.3.3 Each mounting press must have a dial pressure gauge and a pressure recording gauge. Pro-
tection from shocks is afforded the recording gauges if they are mounted separate from the press.
The recording gauge may be of the type that traces the increase in pressure either by inch of ram
travel or by time per ram travel. The pressure diagram should be as shown in the Segment 4.0.
This gives a valuable graphic record of the operation that serves not only as a check on the quan-
tity and quality of the output but also provides protection for the shop if trouble develops later on
the road. These records should be checked daily by the foreman and filed in such a way as to be
easily available at any time. These records will be maintained for 5 years. One recording gauge is
sufficient if wheels are pressed on singly. It is advantageous to use two gauges with a two-ram
press and thus mount two wheels at the same time. With such an arrangement, the recording
gauges are mounted separate from the machine. The recording pen should be kept clean and
replaced when necessary in order to ensure a thin, clear line. If the same press is used for mount-
ing and dismounting the dial pressure gauge, then the pressure recording gauge should be discon-
nected when the press is being used for dismounting
2/1/04
2/1/04 G-II19
SEGMENT 2.0 RP-631
Car owners are to keep a record of the marking of wheels and axles under new cars. This record is
to be kept on file for a minimum period of 5 years.
2.3.4 All wheels must be mounted within the pressure limits as shown in Fig. 4.19. These limits
are of wide range and should therefore be strictly adhered to in all cases. If the pressures are con-
sistently too high or too low, the pressure gauge should be calibrated, the fit allowances should be
checked with micrometers, and the lubricant should be examined for proper consistency. Tests
have proven that in mounting wheels with the same fit allowance, one pair mounted with a lubri-
cant having too much white lead will develop a considerably lower tonnage than a pair mounted
with lubricant of the proper consistency.
2.3.5 The shape of the pressure diagram as well as the maximum pressure reached is an indica-
tion of the character of the fit. The mounting chart ensures that the tonnage required by the press
is actually being used to overcome the interference fit between the axle and wheel over the entire
length of the wheel bore. Other types of friction that contribute to false tonnage include
misalignment between the axle seat and the wheel bore
galling of wheel seat or bore
improper chamfer on the wheel seat or entry taper on the bore
excessive positive taper
not enough or the wrong type of lubricant
obstructions coming in contact with the press ram.
Conversely, conditions that contribute to tonnage drop-offs include
too much lubricant
incompatible finishes between the wheel and axle mating surfaces
negative taper
Were it not for these variables, the dial gauge would suffice as the sole accept/reject authority. For-
tunately, the shape of the mounting diagram indicates when these conditions exist. Figs. 4.22
through 4.29 give examples of both acceptable and unacceptable mounting charts and the condi-
tions they expose. Fig. 4.21 describes how to construct a GONO GO template that is recom-
mended for determining whether or not the mounts meet the accept or reject criteria given by Rule
1.4.1. The resultant template shown in Fig. 4.21, Step 5, is unique to the mounting press and
recording system on which it is constructed. It will only need reconstructing if dimension A
changes as the result of machinery or feed rate changes. Once constructed, simply overlay the tem-
plate onto the mounting chart and align with the origins and the top return lines. If the following
conditions are met, the mount is acceptable:
Doesnt touch the red lines
Builds tonnage up to the green line
Peak tonnage is on or inside box (c)
Wheels are in gauge and centered
Final tonnage at the return line is concise and within minimum and maximum tonnage
Once it crosses a blue line it does not cross back through it
2.3.6 The recorder must be maintained and kept properly adjusted at all times. Lost motion in
the recording mechanism will result in error in the length of the fit. Improper adjustment of the
zero reading will cause an error in the pressure records.
2.3.7 The journal protective guards should be of softer material than the axle or lined with soft
material so there will be no danger of their nicking or scratching the journal surfaces. A good form
of guard is made of 1/16-in. sheet steel sections hinged together with a 3-in. 3-in. steel butt hinge
welded to the shield. Six projecting bars 1/2 in. high and 3/4 in. wide, with a bevel at both ends, are
spot welded to the outside of the shield. These bars serve to guide the wheel as it is pressed on the
2/1/04
G-II20 2/1/04
SEGMENT 2.0 RP-631
axle, reducing the possibility of the wheel starting on the axle at an angle, which may result in
damage to the wheel bore or the axle wheel seat and in improper mounting of the wheel.
2.3.8 As protection against abnormal flange wear and interference with track structures, it is
necessary to have correct spacing of wheels on the axle. Wheels must be mounted equidistant from
the center of the axle, which is first located and marked by use of a suitable gauge similar to that
shown in Figs. 4.30 through 4.33. The first wheel is located on the axle by use of the gauge and
shown in Figs. 4.30 through 4.33, or equivalent. Separate gauges having a single length dimension
should be used, and the gauges must be properly marked to show the flange width (wide or nar-
row) for which they are intended. This gauge controls the measurement from the back of the flange
to the center of the axle and is dimensioned to provide the maximum permissible back-to-center
spacing as follows:
Freight car wheels and wide flange passenger car wheels26 35/64 in.
Narrow flange wheels other than freight car26 11/16 in.
The first wheel must be mounted by use of a gauge of this type that gauges from the center of the
axle. The mate wheel may also be mounted using the same gauge or can be spaced from the first
wheel by use of a mounting and check gauge (Figs. 4.30 through 4.33). In mounting the mate
wheel, it may be necessary to mount to some dimension under the above maximum because of
variation in the plane of the back face of the rim. In mounting narrow flange wheels, it may be
preferable to mount both wheels to a lesser dimension.
2.3.9 The wheel should not be cocked as it starts on the wheel seat. The taper at the entry end of
the wheel seat and chamfering of the entry end of the bore will usually correct any tendency of the
wheel to cock and jam. The ends of the rams and sleeves should be checked to ensure they are
smooth and properly squared.
2.3.10 Working drawings for suitable wheel mounting gauges are shown in paragraph 5.0.
Wheels are to be mounted and checked on the basis of back-to-back measurement using these or
similar gauges. The maximum back-to-back mounting distance for all freight car wheels and wide
flange passenger car wheels is 53 3/32 in. Narrow flange passenger car wheels may also be
mounted to this distance if desired. The maximum back-to-back distance for narrow flange wheels
on other than freight cars is 53 3/8 in. A minus tolerance is allowed to a minimum limit of 53 in.
back-to-back for all wheels. However, since 53 in. is the minimum permitted at any point on the
circumference of the wheels, it is desirable to mount toward the larger dimension (see Figs. 4.30
through 4.33). After the wheels are mounted, the gauge should be tried at three or more equidis-
tant points around the circumference to be sure the wheels are within the gauge limits.
2.3.11 Wheel mounting and check gauges should be checked weekly so excessive wear will not
allow improper mounting of wheels.
2.3.12 When boiled linseed oil only is used as mounting lubricant, it is recommended that a color-
ing agent be used in order to ensure proper coating of wheel seat and bore. Color 26105, ASTM
D-910, is suggested.
2.4 Wheel Lathe Practices
2.4.1 The restoring of wheel contours is to correct service defects such as thin flange, vertical
flange, high flange, worn tread, built-up tread, and slid-flat spots. It is important that only the
necessary service metal be removed to restore contours. A very small amount of wasted service
metal means a loss of considerable mileage.
2.4.2 It is very important to determine the wheel defect and the necessary amount of service
metal to remove to restore wheels to proper contour. The AAR steel wheel gauge, Figs. 5.1 and 5.4,
is very beneficial in determining this information. Proper use of the gauge is as follows:
2.4.2.1 The AAR steel wheel gauge is so calibrated that when applied with the leg flat against the
back of the rim and the end of the movable finger pressed against the face of the flange, the scale
2/1/04
2/1/04 G-II21
SEGMENT 2.0 RP-631
on the finger will read directly in sixteenths of an inch the amount of metal to be removed at the
center of the tread to restore full flange contour with a witness groove.
2.4.2.2 Apply the gauge to at least three points around the circumference of each wheel to deter-
mine where rim and flange are the thinnest, taking finger readings and rim thickness readings for
determination of tread removal at the thinnest point.
2.4.2.3 To restore flange thickness, the amount of sixteenths shown on the finger below 0 (on
NF finger) indicates number of sixteenths of service metal to be removed to restore flange to 0
(on NF finger). Deduct this amount from the rim thickness reading on the scale of the back leg to
determine the remaining amount of service metal after turning.
2.4.2.4 Wheels requiring recontouring for other defects with flange thicknesses greater than 0
(on NF finger) should have enough service metal removed only to correct the defect, leaving the
flange as near 1 3/8 in. maximum as possible.
2.4.2.5 When restoring contours to wheels with defects such as slid-flat, built-up tread, shelling,
or grooving, before determining the amount of service metal to be removed, flange thicknesses
should be taken into consideration. That is, to restore the contour to a wheel that has a slid-flat
spot (or spots), a reading should be taken with the steel wheel gauge in the center of the slid-flat
spot noting the thickness of the rim on the back leg of this gauge. Another reading should be taken
in the good part of the wheel, and the difference between these two readings is the amount of ser-
vice metal necessary to remove the slid flat spot. At the same time, a reading should be taken with
the movable finger to determine flange thickness as per paragraph 2.4.2.3 above. The greatest of
these two readings will determine the actual amount of service metal to be removed to restore the
wheel to acceptable contour.
2.4.3 The witness groove in the flange serves two purposes (see figures in paragraph 4.0 of this
manual). First, its presence in the finish-turned wheel shows the lathe operator has not wasted
service metal by turning more off the tread than necessary. Second, it permits the saving of about
1/8 in. of service metal each time a wheel is turned, if the wheel has a thin or vertical flange. This
witness groove, however, must not be more than 3/64 in. deep and must not extend into the
throat of the flange, gauged as shown in Figs. 4.47 and 4.48. Due to the importance of the throat in
wheel service and safety, it is essential these limits for the witness groove be observed.
2.4.4 Wheels not meeting profile limits must be scrapped or recontoured.
2.5 Wheel Shop Inspection
2.5.1 One of the most important functions in the wheel shop is inspection. Inspection requires
good judgment and a knowledge of all the phases of wheel and axle work. All wheels and axles that
enter the wheel shop should be inspected for defects. Any wheel or axle with a defect that cannot
be removed by machining within the prescribed tolerances should be scrapped immediately to pre-
vent loss of time and money in attempts to machine it. Wheels and axles that are to be machined
must be segregated with respect to the work to be performed. All wheels and axles that have been
reconditioned should be inspected to ensure the defects have been removed and they are within
the prescribed tolerances for further service. When testing axle journal finish with an electronic
microinch tester, the cut-off switch must be set at 0.030, or an equivalent measuring
method/device should be used.
2.5.2 Axles should be demagnetized before bearings are reapplied. If it is necessary or desired to
magnetic particle test the body of the axle, the best results can be obtained when the surfaces of
the axles are cleaned of rust, oil, paint, and dirt prior to testing. Such cleaning can be accom-
plished by a rotary wire brush, sand or shot blasting, or by flame cleaning. Flame cleaning should
be performed on a machine designed for that purpose to avoid excessive localized heating.
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SEGMENT 2.0 RP-631
2.5.3 Nondestructive Inspection of Axles
2.5.3.1 The wet method magnetic particle testing equipment used in wheel shops for testing axles
consists of a unit using a bath made of a suitable carrier and fine fluorescent-coated magnetic par-
ticles, with an agitation system to keep particles in suspension, a high amperage low voltage
transformer, high amperage magnetizing coil, and an ultraviolet light source.
2.5.3.1.1 A pressurized spray can with a prepared batch containing a suspension of fluorescent
magnetic particles in a light oil may be used provided the spray can is vigorously shaken before
each application to ensure magnetic particles are in suspension.
2.5.3.1.2 At all wheel shops, the wet method magnetic particle axle testing equipment used for
unmounted or mounted wheel sets must conform to the following minimum requirements:
2.5.3.1.2.1 A minimum magnetizing source of 800 amperes AC of low voltage.
2.5.3.1.2.2 A magnetizing coil of circular shape, the diameter of which should not exceed 18 in.,
capable of producing a 4000-ampere-turns minimum magnetizing force.
2.5.3.1.2.3 A bath of adequate quantity of a suitable carrier and fluorescent-coated magnetic par-
ticles maintained suitably and freely in suspension by an agitation system. A prepared bath in a
pressurized spray can may be used with proper agitation. The carrier used should meet ASTM
E-709 requirements.
2.5.3.1.2.4 A near ultraviolet light source radiating through a suitable filter, radiation of a wave
length from 4000 to 3400 and of 75-footcandle intensity at the point of inspection.
2.5.3.1.2.5 The axle-testing installation must not allow outside sources of light exceeding 10-foot-
candle intensity to reach the area of inspection.
2.5.3.1.2.6 The test equipment manufacturers instructions should be available for reference.
2.5.3.1.3 When the magnetizing coil, with current on, is positioned over a specific area of an axle,
a longitudinal magnetic field, mainly parallel to the axle centerline, is produced at the surface of
the axle. This magnetic field will cause fluorescent magnetic particles to gather heavily at the con-
tour of superficial cracks oriented primarily in a circumferential direction within the specific area
covered by the coil.
2.5.3.2 In testing axles, the magnetizing coil is brought over the center of the area to be tested
and magnetism is applied to the area at the same time as the bath solution is applied. During the
time magnetism and bath solution are applied, the axle is rotated so the entire surface is well-cov-
ered. After thorough coverage of the inspection area with fluid, the solution is cut off while current
remains on for a short while (approximately 3 seconds), avoiding possible washing off of small indi-
cations. The ultraviolet (black light) light is passed over the area and the axle is rotated slowly
while a visual inspection is being made. It is recommended that the axle be rotated two complete
turns during this inspection.
2.5.3.3 The bath or solution should be prepared and renewed monthly or more often, if contami-
nation is noted in weekly tests. Each time the bath is renewed, the bath container should be
cleaned out and the agitation and circulation system should be flushed with one or two gallons of a
suitable cleaner. Filtering screens should be removed and cleaned by blowing with air. In prepar-
ing the new bath, only recommended materials should be used. The amount of powder should be
carefully weighed out in accordance with the material manufacturers recommendation and added
directly to the bath containing the correct amount of carrier. It is recommended that powder be
added directly over the sump so it will be drawn quickly into the pump and circulated. The amount
of carrier and powder used and the date of preparation should be recorded on a regular form set up
for this purpose, as outlined in paragraph 2.5.3.6 below.
2.5.3.4 The ultraviolet light should be tested weekly using a sight meter such as a type having a
75-footcandle scale with a 10 multiplying disc or equivalent or a meter that responds specifically
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SEGMENT 2.0 RP-631
to the ultraviolet range of 3650 units (365 nm). The latter type meters are calibrated in micro-
watts per square centimeter. The meter should be held a fixed distance of 15 in. from the light
source (from the black light filter surface to the meter sensing element) and should have a mini-
mum meter reading of 525 W/cm
2
. The conversion factor from footcandles (for sight meters) to
microwatts per square centimeter is 5.7 times the footcandle reading (at 15-in. distance).
2.5.3.5 The maximum allowable footcandles will be left to the discretion of the user dependent on
the degree of brilliance desired to obtain satisfactory inspection conditions. Before taking a read-
ing, it should be known that the glass black light filters are clean. Reports of this test are to be
shown on a regular form.
2.5.3.6 A regular form should be prepared embodying the information to be shown on monthly
and weekly tests as outlined above, and this form should be on hand at the wheel shop and avail-
able to AAR inspectors. If desired, this form may be incorporated with the regular equipment
inspection form outlined in this manual.
2.5.4 Form MD11A is a recommended format; other formats that collect equipment data may be
used. Also attached are helpful hints and a bearing inspection flowchart to assist in collecting
these data. Data on Form MD11A will be transferred to Form MD11, which will be filed with the
AAR. The following steps should be followed in conjunction with collecting data as shown on Form
MD11A (Recommended Bearing Inspection Report).
2.5.4.1 Check the wheel set for wheel and axle defects. Report and record defects per Why Made
Codes in the Field Manual of the AAR Interchange Rules, Rules 41 and 43. Inspect the narrow adapter
for excessive wear according to the Field Manual of the AAR Interchange Rules, Rule 37, and for other
abnormal conditions.
2.5.4.2 Record the roller bearing condition, such as fused, missing, burn-off, blued, bolts or end
cap missing; or seal missing, cocked, or damaged.
2.5.4.3 Record the certificate number, date of manufacture, end cap manufacturer, and locking
plate information of each bearing. Missing or illegible information should be noted. Do not leave
boxes blank.
2.5.4.4 Check the backing ring for looseness by lightly tapping it with a 1-lb hammer. Check and
record the lateral of each bearing. Measure the break-away torque (in the clockwise direction) for
each cap screw. The preferred method for checking torque is as follows:
2.5.4.5 Remove the end cap and demount the roller bearing. Record the axle identification infor-
mation and note whether or not the cap screw rings were present. Check the axle for bent condi-
tion.
2.5.4.6 Check and record the axle journal for evidence of fretting wear due to cone and/or wear
ring movement. Check the axle fillet radius for corrosion.
2.5.4.7 Measure and record journal diameters in the cone seat areas in accordance with Fig. 4.5.
1. Mark the cap screw head location.
2. Unbend the locking tabs.
3. Loosen one cap screw 1/16th of a turn.
4. Using a calibrated (dial or digital) torque wrench, retorque the cap screw to the
marked position and record the torque. Leave the cap screw in the torqued posi-
tion until Step 5 is completed.
5. Repeat Step 3 and Step 4 for the other two cap screws.
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SEGMENT 2.0 RP-631
2.6 Teardown
2.6.1 Roller Bearing and Journal Inspection
2.6.1.1 Visually check the exterior of the bearing, cap screws, axle end cap, and backing ring for
evidence of damage.
2.6.1.2 Disassemble the roller bearing, ensuring that components are kept together as a unit.
Inspect the seals for wear, nicks, etc., and record the seal manufacturer name and the date.
2.6.1.3 Visually check and record the condition of the grease for quantity, distribution, consis-
tency, color, and evidence of water or other contamination.
2.6.1.4 Degrease, clean, and visually inspect roller assemblies, outer rings, and other component
parts.
2.6.1.5 Measure and record inboard and outboard cone back face wear depth. Visually inspect for
fretting wear or wear due to relative movement.
2.7 MD-11 Reporting
After the Form MD11A has been completed and the information transferred, submit Form MD-11
to the AAR in accordance with Rule 1.7.11. Analyze all information to determine the defect that
initiated the failure. Do not confuse symptoms with the root causes.
EXAMPLES
Helpful Hints for Causes of Hot Boxes
Initial
Defect
Cause
of Heat
1. A loose cap screw, loose backing ring, undersize journal, or worn cone face
may allow cones to move on the journal and possibly cause the roller to spall
or fracture.
CA1 CN4
2. Water etch brinelling, etc., may result in heavy damage to seal lips. Grease
that will leak from the bearing and foreign matter will enter.
CU3 LU1
3. A journal with an upset end may stretch the cone bores causing the cone to
fracture or move on the journal.
JR2 CN4
4. Seal loose, cut, ruptured, worn, or casing dented will allow grease to leak out
of the bearing and foreign matter to enter.
SE1 LU1
5. A bearing overheated from an external heat source will show signs of seal
rubber embrittled and the grease may have a hardened or dry appearance.
BE2 LU1
6. A defective adapter will cause an uneven load distribution on the bearing
assembly.
AD1 CU2
7. A cap screw too long or a defective cap screw hole (dirty, rusty, partially
closed, or faulty threads) will not provide adequate clamping force. There-
fore, the bearing will become loose on the journal while in service.
CA2 CN4
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2/1/04 G-II25
SEGMENT 2.0 RP-631
Bearing inspection flowchart
Fig. 2.1
HOT
BEARING
CAGE
CONTACT
WITH SEAL
CASE
SEAL LIPS
HARD AND
BRITTLE
GREASED
HAS
BURNED
ODOR
GREASED,
DRY, HARD,
CAKED
BEARING
SEIZED
C
See
Fig. 2.4
D
See
Fig. 2.5
E
See
Fig. 2.6
Abbreviations:
OB OutboardRaceway location
IB InboardRaceway location
OD Outside diameter
ID Inside diameter
A
See
Fig. 2.2
B
See
Fig. 2.3
BEARING
PARTS
HEAT DIS-
COLORED
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G-II26 2/1/04
SEGMENT 2.0 RP-631
Bearing inspection flowchart, part A
Fig. 2.2
OBSERVATION/INITIAL DEFECT:
OB CUP SMALL ID SPALLING
OB ROLLER SMALL END SPALLING
IB CONE BORE FRETTING
IB JOURNAL FRETTING
HEAVY IB CONE FACE WEAR
BACKING RING RADIUS FRETTING
REDDISH DISCOLORATION OF
GREASE (IRON OXIDE)
OBSERVATION:
WELDING DEBRIS ON BEARING
ARC DAMAGE ON BEARING RACES
HEAT DISCOLORATION
BRITTLE SEAL LIPS
MISALIGNMENT OF
BEARING COMPONENTS
EXTERNAL HEAT
CONCLUSION:
AXLE FLEXURE
CONCLUSIONS:
IMPROPER GROUNDING FOR WELDING
THAWING SHED DAMAGE
EXTERNAL HEAT
MD-11 CODES:
CM 1 Components (load carrying)
mixed manufacturers
CN 4 Cone revolving on journal
JR 1 Journal undersize
UN 1 Undetermined (but hot)
MD-11 CODES:
BE 2 Bearing overheated from
external fire or heat
EL 1 Electric arc burns
SE 6 Seal, rubber brittle
A
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SEGMENT 2.0 RP-631
Bearing inspection flowchart, part B
Fig. 2.3
EXCESSIVE CONCENTRATED LOADING
CONCLUSION:
BEARING NOT SEATED
AT INSTALLATION
END CAP INSTALLATION
NOT PROPER
CAP SCREW(S) LOOSE
OR MISSING
CONCLUSIONS:
INCORRECT SPACER
MD-11 CODES:
CA 1 Cap screw, loose or
missing
CA 2 Cap screw, length
excessive
CA 3 Cap screw hole, rusty
or faulty threads
UN 1 Undetermined
(but hot)
MOUNTED LATERAL OUT OF
TOLERANCE
OBSERVATION:
MOUNTED LATERAL >
BENCH LATERAL
CONES SPREAD
OBSERVATION:
COMPONENTS NOT
HEAVILY WORN
OBSERVATION:
HARD TO ROTATE
(NO FATIGUE OR OTHER
SURFACE DAMAGE)
EXCESSIVE BENCH LATERAL
BEARING PRELOAD
CONCLUSION:
INCORRECT SPACER
UNDERSIZE CONE BORE
OVERSIZE JOURNAL
MD-11 CODES:
LE 1 Excessive lateral
cones, backing ring
and bolts tight
UN 1 Undetermined
(but hot)
MD-11 CODES:
JR 2 Journal upset end
JR 3 Journal oversize
UN 1 Undetermined
(but hot)
B
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SEGMENT 2.0 RP-631
Bearing inspection flowchart, part C
Fig. 2.4
OBSERVATION:
CUP CRACKED/BROKEN
BACKING RING OD DAMAGED
END CAP OD DAMAGED
IRREGULAR ADAPTER CONTACT
MD-11 CODES:
AD 1 Adapter, defective
AD 2 Adapter, displaced
AD 3 Adapter, worn
AD 4 Adapter, wrong size or
missing
BE 3 Bearing, wrong size
CU 1 Cup, broken or dented
MD-11 CODES:
CN 1 Cone, broken
RO 1 Roller defective, broken
RO 2 Roller defective, other
CG 1 Cage, defective
CU 1 Cup, broken or dented
BROKEN PARTS
OBSERVATION:
BRINELLING
BARLINE SPALLS
CAGE BROKEN
ROLLER(S) BROKEN
OBSERVATION:
DISPLACED ADAPTER
ADAPTER BORE OUT OF
TOLERANCE
WRONG SIZE ADAPTER
ADAPTER SEVERELY WORN
EXTERNAL MECHANICAL DAMAGE
OBSERVATION:
HIGH IMPACT LOADS
WHEEL DEFECTS
IMPROPER CAR HANDLING
C
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SEGMENT 2.0 RP-631
Bearing inspection flowchart, part D
Fig. 2.5
OBSERVATION:
ROLLER END WEAR OR SCORING
HEAT DISCOLORATION
MD-11 CODES:
LU 1 Lubricant, missing or
depleted
MD-11 CODES:
LU 1 Lubricant, missing or
depleted
SE 1 Seal, loose
SE 2 Seal, cocked out-of-position
SE 3 Seal (casing) cut or dented
SE 4 Seal, rubber lips worn out
SE 5 Seal, rubber lips torn or
rotted
CU 3 Cup, raceway heavily water
etched
LUBRICANT PERFORMANCE
OBSERVATION:
ROLLER END WEAR OR SCORING
WATER ETCHING
ROLLER SPACED BARLINE SPALLS
HEAT DISCOLORATION
CONCLUSION:
INADEQUATE CHARGE
CONCLUSION:
SEAL DAMAGED
SEAL LOOSE OR DISPLACED
SEAL EXCESSIVELY WORN
MISSING DEPLETED
D
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G-II30 2/1/04
SEGMENT 2.0 RP-631
Bearing inspection flowchart, part E
Fig. 2.6
OBSERVATION:
ABRASIVE WEAR
FRETTING DEBRIS
REDDISH DISCOLORATION
OF GREASE (IRON OXIDE)
AXLE GROOVING
CONE BORE FRETTING
MD-11 CODES:
CN 4 Cone, revolving
on journal
CN 5 Cone, (inner), face
heavily worn
JR 1 Journal undersize
UN 1 Undetermined
(but hot)
CONTAMINATED
CONCLUSION:
AXLE FLEXURE
INTERNAL DEBRIS EXTERNAL INGRESS
OBSERVATION:
WATER ETCHING
ROLLER SPACED BAR LINE
SPALLS
DAMAGED SEAL(S)
CORROSIONBACKING
RING RADIUS
CORRODED JOURNAL
HEAVY SEAL LIP WEAR
CORRODED SEAL WEAR
RING OD
OBSERVATION:
ABRASIVE WEAR
DAMAGED SEAL(S)
CONCLUSION:
WATER INGRESS
CONCLUSION:
CONTAMINANT INGRESS
OTHER THAN WATER
MD-11 CODES:
SE 1 Seal, loose
SE 2 Seal, cocked
out-of-position
SE 3 Seal (casing) cut or
dented
SE 4 Seal, rubber lips worn
out
SE 5 Seal, rubber lips torn
or rotted
CU 3 Cup, raceway heavily
water etched
UN 1 Undetermined
(but hot)
MD-11 CODES:
SE 1 Seal, loose
SE 2 Seal, cocked
out-of-position
SE 3 Seal (casing) cut or
dented
SE 4 Seal, rubber lips worn
out
SE 5 Seal, rubber lips torn
or rotted
UN 2 Unlisted cause
UN 1 Undetermined
(but hot)
E
2/1/04
2/1/04 G-II31
SEGMENT 2.0 RP-631
Fig. 2.7 AAR MD-11A Recommended Bearing Inspection Report
AAR MD-11A RECOMMENDED BEARING INSPECTION REPORT
Part 1External Inspection
Inspection Location: Inspection Date: Fail Date:
Car Initial: Car Number: Position: Car Type: WM Code:
Bearing Size: Mfg: S/N Month Year S/N NFL:
Hot or Mate (H or M): Journal Burn Off: How Detected: Mount By:
End Cap Style: Shroud B/R: Fit B/R: Fit Appl: B/R Loose: Lateral:
End Cap Condition: Backing Ring Condition:
Torque: / / Axle S/N: Axle Mfg: Axle Date:
Wheel S/N W/Class: W/Mfg: W/Date: Hub/Date:
* Journal Size OB Cone: Spacer: IB Cone: Upset:
Journal Condition:
Journal Fretting @ IB Wear Ring: Groove Depth:
Wheel Condition and Why Made Code:
Adapter Condition:
Part 2Internal Inspection
Times Cup Reconditioned: Cup Last Reconditioned:
Cup Reconditioned By: Shop: Cup Reground On:
Cup Condition: IB:
OB:
Cone Renamed: IB: OB: Cone Plated By: IB: Shop:
Date Cone Plated: IB: OB: Cone Plated By: IB: Shop:
Cone Reground: IB: OB: Cone Reground Date: IB: OB:
Cone: IB-Date: Cond:
Face Wear:
OB-Date: Cond:
Face Wear:
IB Seal Mfg: IB Seal Date: IB Cond:
OB Seal Mfg: OB Seal Date: OB Cond:
WR IB-Mfg: Date: Cond:
OB-Mfg: Date: Cond:
Spacer Condition
Grease Condition
O Rings: O Rings Removed: By: Hot: ID No.
Comments/Conclusions:
* (Enter journal size if found to
be out of specification.)
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SEGMENT 2.0 RP-631
AAR-MD11A BEARING INSPECTION INSTRUCTIONS
INSPECTION LOCATION: The location and railroad of inspection
INSP DATE: The date of external inspection
FAIL DATE: Date bearing was removed from service
CAR INITIAL: Letter designation on car
CAR NUMBER: Two- to six-digit number following car initial
POSITION: Left or right side of car, axle count from B end of car
CAR TYPE: B=Box, T=Tank, F=Flat, L=Covered Hopper, G=Gondola,
S=Stock, R=Refrigerator, C=Caboose, A=Articulated, O=Other
WM CODE: AAR Bearing Why Made Removal Code 50 or 95, located in the
Field Manual of the AAR Interchange Rules, Rule 36
BRG SIZE: Marked on end cap of bearing
5 1/2 in. 10 in. = 10
6 in. 11 in. = 11
6 1/2 in. 12 in. = 12
7 in. 12 in. = G
MFG: Bearing manufacturer, located on outside of cup, not endcap
SERIAL
NUMBER/MONTH:
Month of bearing manufacture, located on outside of cup, either a
two-digit number or one-digit letter
YEAR: Year of bearing manufacture, located on outside of cup
S/N: Bearing serial number located on outside of cup
NFL: No Field Lube; indicating no grease fitting (Y or N)
HOT OR MATE(H or M): Designates between hot bearing and its mate
JOURNAL BURN OFF: Bearing burnt off axle (Y or N)
HOW DETECTED: Bearing detected by hot box detector (D) or other means (X)
MOUNT BY: AAR-approved wheelshop for the application of roller bearings;
two- to five-letter code.
END CAP STYLE:
SHROUD B/R: Is backing ring of shrouded design (Y or N)
FIT B/R: Is backing ring of fitted design (Y or N)
FIT APPL: Are dust guard seat and backing ring of fitted design (Y or N)
B/R LOOSE: Was backing ring loose during service (Y or N)
LATERAL: Bearing lateral before removal from journal
END CAP CONDITION: Condition of end cap
BACKING RING
CONDITION:
Condition of backing ring
TORQUE: Measure break-away torque with dial or digital type torque
wrench
AXLE SERIAL #: Axle serial number displayed on end of journal
AXLE MFG: Manufacturer of axle displayed on end of journal
AXLE DATE: Date axle was manufactured displayed on end of journal
WHEEL SERIAL #: Wheel serial number
WHEEL CLASS: Letter designation on wheel (B, C, U) specifying heat treatment
W/MFG: One- or two-letter code designating wheel manufacturer
2/1/04
2/1/04 G-II33
SEGMENT 2.0 RP-631
2.8 Steel Wheel Defects
2.8.1 This section contains information on service defects occurring in wheels. The defects are
described and illustrated to provide terminal inspectors and wheel shop men with a guide for the
removal and disposition of such wheels, see Figs. 4.53 through 4.60.
2.8.2 All wheel defects referred to in the following table are covered in the references in the Field
Manual of the AAR Interchange Rules and/or figure numbers in this manual.
W/DATE: Date wheel was manufactured
HUB DATE: Date and wheelshop when wheels were applied to axle
OB CONE: Measure the journal diameter according to the AAR Manual of
Standards and Practices, Section G, Part II
SPACER: Measure the journal diameter according to the AAR Manual of
IB CONE: Measure the journal diameter according to the AAR Manual of
UPSET: Is journal upset according to the AAR Manual of Standards and
Practices Section, G, Part II (Y or N)
JOURNAL CONDITION: General condition of journal
JOURNAL FRETTING Is a visibly polished groove on the journal where the inboard wear
ring is located (Y or N)
GROOVE DEPTH: Depth of inboard wear ring groove into journal, if measurable
WHEEL CONDITION AND
WHY MADE CODE:
Condition and Why Made code of wheel
ADAPTER CONDITION: Condition of adapter, see the Field Manual of the AAR Interchange
Rules, Rule 37
Defect
Field Manual
Rule
AAR Why
Made Code
Figure Number
Obsolete Material Rule 41 07
Thin Flange Rule 41 60
Vertical Flange Rule 41 62 4.51, 4.52
High Flange Rule 41 64 4.51, 4.52
Cracked or Broken Flange Rule 41 66
Out of Round Rule 41 67
Cracked or Broken Rim Rule 41 68
Shattered Rim Rule 41 71 4.53
Spread Rim Rule 41 72 4.56
Thin Rim Rule 41 73
Thermal Cracks Rule 41 74 4.54, 4.55
Shelled Tread Rule 41 75 4.57
Built-Up Tread Rule 41 76 4.57
Grooved Tread Rule 41 77 4.58
Slid Flat Rule 41 78 4.57
Scrape, Dent, or Gouge in Wheel Surfaces Rule 41 80 4.60
AAR-MD11A BEARING INSPECTION INSTRUCTIONS
2/1/04
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SEGMENT 2.0 RP-631
2.8.3 Shattered Rim
2.8.3.1 If the break shows a fracture as shown in Fig. 4.53, the wheel is said to have a shattered
rim.
2.8.3.2 If a circumferential crack is found on the front or back face of the rim, the wheel must be
removed from service. This type of crack is an indication of a shattered rim not yet fully developed.
Wheels in road diesel and other services subject to shattered rim failure should be inspected
closely for such cracks so that, when present, the wheel may be removed before a piece of tread
actually breaks out.
2.8.4 Spread Rim
If the rim widens out for a short distance on the front face, an internal defect may be present
and the wheel must be withdrawn from service (see Fig. 4.56). Spreading of the rim is usually
accompanied by a flattening of the tread and may or may not have cracks or shelling on the
tread. This condition is probably associated with shattered rim. It is usually less than 12 in.
long and should not be confused with the uniform curling over of the outer edge of the rim
around the entire wheel. This latter is a common service condition and is not a defect.
2.8.5 Sub-Surface Defect
If, during the turning of a wheel, voids or a laminated or flaky condition is disclosed under the sur-
face, the wheel has a sub-surface defect. Unless this can be turned out, it should be scrapped, see
Fig. 4.56.
2.8.6 Shelled Tread
2.8.6.1 When pieces of metal break out of the tread surface in several places more or less contin-
uously around the rim, the wheel has a shelled tread (see Fig. 4.57). Unless this defect has pro-
gressed too far, it can generally be turned out, but care must be taken that all evidence of the
defect is eliminated before returning such wheels to service.
2.8.6.2 In services where excessive shelling occurs, it is recommended that remedial measures be
taken. Contributing factors include poor track, excessive speed, excessive loads or the use of
wheels of insufficient hardness.
2.8.7 Thermal Cracks
2.8.7.1 Thermal cracks are caused by intense brake heating. They occur cross-wise on the tread
and may be confined to tread or flange or, in extreme cases, may go through the entire tread and
into the plate (see Figs. 4.54 and 4.55). True thermal cracking is a serious defect, and in any stage
of development it is cause for the immediate removal of the wheel from service.
2.8.7.2 Many shallow thermal cracks can be removed by machining, but extra care must be used
to make certain the crack has been completely eliminated in the operation.
Out of Gauge Rule 41 81 4.29, 4.31,
4.32, and 4.33
Cracked or Broken Plate Rule 41 83 4.59
Holes in Plate Rule 41 84
Loose Rule 41 85
Big Bore Rule 41 86
Insufficient Hub Wall Thickness Rule 41 87
Sub-Surface Defect Rule 41 88 4.56
Defect
Field Manual
Rule
AAR Why
Made Code
Figure Number
2/1/04
2/1/04 G-II35
SEGMENT 2.0 RP-631
2.8.7.3 If a wheel is found with a radial crack on the back or front face of the rim, it should be
removed from service under the thermal crack rule. Such cracks often originate in hot stamp
marks, lathe dog or chuck marks, or miscellaneous nicks or surface defects on the rim faces. They
tend to progress and may ultimately lead to wheel failures as shown in Fig. 4.55.
2.8.7.4 In classes of service where excessive thermal cracking occurs in wheels, heat-treated
wheels of lower carbon content have proven helpful in overcoming the defect.
2.8.7.5 Brake shoe heating frequently produces a fine network of superficial lines or heat checks
running in all directions on the surface of the wheel tread (see Fig. 4.54). This is sometimes associ-
ated with small skid burns. It should not be confused with true thermal cracking and is not nor-
mally a cause for wheel removal.
2.8.7.6 Another tread condition is known as spalling. Spalling is the result of small portions of
metal breaking out between or adjacent to fine thermal checks that, in turn, may be associated
with small skid marks or chain sliding. While spalling is not considered a condemnable defect,
many railroads remove such wheels from their own equipment and machine the treads down to
sound metal. This would apply particularly to multiple-wear wheels and relatively new one-wear
wheels.
2.8.8 Slid Flat
A slid flat wheel is condemnable when the flat spot is 2 in. or over in length, measured circumfer-
entially, or if there are two or more adjoining flat spots 1 1/2 in. or over in length (see Fig. 4.57).
This applies to all kinds of wheels in freight car service.
2.8.9 Built-Up Tread
A built-up tread is caused by metal from the tread or the brake shoe being heated to the plastic
state and then dragged or built-up around the tread. The condition is generally associated with
sliding on the rail. Such wheels must be removed from service when buildup is 1/8 in. or higher.
Examples of this defect are shown in Fig. 4.57. Turning the treads of such wheels requires special
attention and is hard on cutting tools. Experience indicates the cut will have to be made at least
1/16 in. and preferably 3/32 in. to 1/8 in. below the lowest point on the tread.
2.8.10 Thin Flange
The minimum flange thickness for steel wheels in service is 15/16 in. as determined by the gauge
shown in Figs. 5.8 and 5.10.
2.8.11 Vertical Flange
A wheel is condemnable for vertical flange when the gauge applied, as in Figs. 4.51 and 4.52. con-
tacts the throat side of the flange 1 in. above the tread.
2.8.12 High Flange
The maximum flange height for steel wheels in service is 1 1/2 in. measured as shown in Figs. 4.51
and 4.52.
2.8.13 Cracked or Broken Flange
Cracked or broken flanges are rare on steel wheels. When they do develop, the wheel is condem-
nable and must be removed immediately.
2.8.14 Cracked or Broken Rim
Chips broken from the uniform curling over of the outer edge of the rim around the entire wheel
are not considered a defect.
2.8.15 Cracked or Broken Plate
A wheel with a cracked plate must be condemned. Cracks in the plate develop due to stresses from
service loads and braking in combination with internal stresses in the wheel and possibly surface
defects in areas subject to high stresses. Most plate cracks are progressive in nature and it is
2/1/04
G-II36 2/1/04
SEGMENT 2.0 RP-631
important they be detected in their early stages. Fig. 4.59 shows a typical plate crack that has not
extended into the rim section at either end.
2.8.16 Holes in Plate
Wheels with holes in the plate or showing evidence of application of a torch or electric arc are con-
demnable and must be withdrawn from service.
2.8.17 Loose or Out of Gauge
2.8.17.1 Wheels must be removed from service if they show indications of being loose on axles.
Indications of a loose wheel may be back-to-back measurement exceeding the limits of 52 15/16 in.
minimum to 53 3/8 in. maximum and movement on the wheel seat.
2.8.17.2 Wheels must have gauge measurements in accordance with Figs. 4.30 through 4.33.
2.8.18 Grooved Tread
Wheels that have circumferential groove or grooves in tread to a depth of 1/8 in. or more must be
removed from service (see Fig. 4.58). Wheels having this defect may be reclaimed by turning, pro-
vided the grooves are completely removed.
2.8.19 Scrape, Dent, or Gouge in Wheel Surfaces
Wheels with a scrape, dent, or gouge more than 1/8 in. deep are condemnable (see Fig. 4.60). These
defects create stress risers that can cause wheel failures.
2.8.20 Wheels That Have Been Overheated
2.8.20.1 Wheels that have been overheated as a result of being in a fire must be scrapped. Care
must be exercised not to overheat wheels and axles if an open flame is used to thaw out contents of
cars. Such overheated wheels would be condemnable.
2.8.20.2 Wheels removed from service as a result of Why Made Code 23 shall be immediately
stenciled in 1-in. letters OVERHEATED SCRAP on the inside of both wheel plates and be
scrapped at the wheel shop.
2.8.20.3 Wheel out-of-round is detected by a wheel impact load detector reading greater than
90,000 lb for a single wheel and verified by an AAR-approved gauge or other suitable device. The
detector used must reliably measure peak impacts and provide a printed record of such measure-
ments. The verified out-of-round runout must exceed 0.070 in. Wheels with condemnable slid flat
spots are handling line responsibility and must not be billed as out-of-round.
2.9 Ultrasonic Inspection of Reprofiled Wheels
For detecting internal discontinuities in the rim of all freight car railroad wheels, ultrasonic
inspection shall be made by either the procedures shown below or by an AAR-approved equivalent.
Equipment used in these procedures shall comply with the following requirements.
Each wheel shop having a status code of 5, 6, or 6A shall maintain a documented test method and
procedures for ultrasonic inspection of all freight car railroad wheels manufactured under the
AAR Manual of Standards and Recommended Practices, Section G, Specification M-107/208.
2.9.1 Equipment
2.9.1.1 The equipment used shall be an ultrasonic pulse echo broadband instrument.
2.9.1.2 The transducer used shall operate at a frequency of 5 MHz nominal and shall be of the
type whose composition and dimensions are appropriate for the test method used.
2.9.1.3 The ultrasonic inspection shall be performed with a system incorporating an automatic
flaw alarm. The system shall produce indications from all rejectable flaws with a signal-to-noise
ratio of 15 dB or greater at all depths between 1/2 in. and 2 in.
2/1/04
2/1/04 G-II37
SEGMENT 2.0 RP-631
2.9.1.4 A suitable couplant shall be used between the test surface and the transducer. The cou-
plant shall be free of air bubbles. Rust inhibitors, softeners, and wetting agents may be added to
the couplant.
2.9.2 Time of Inspection
Inspection shall be performed after final machining.
2.9.3 Calibration
2.9.3.1 Calibration shall be conducted using a reference standard of a wheel or portion of a wheel
rim containing simulated defects or other AAR-approved procedure.
2.9.3.2 For radial testing, the reference standard shall include 1/8-in.-diameter flat-bottom holes
generated from the inside diameter of the rim perpendicular to the tread surface. A minimum of
three holes will be located 1 in., 2 1/4 in., and 3 1/2 in. from the front face of the rim to ensure cov-
erage over the width of the tread. See Fig. 2.8.
Radial rim test, volumetric coverage
Paragraph 2.9.3.2
Fig. 2.8
3"
2"
1"
Typical Reference Standard for Rim Tread Ultrasonic Test
2/1/04
G-II38 2/1/04
SEGMENT 2.0 RP-631
2.9.3.3 A distance amplitude correction (DAC) shall be used for radial testing of wheels. Holes
shall not be located close to each other so as to impede the response from each hole individually.
The holes for the DAC generation shall be located at depths to accommodate the individual sys-
tems response including at least two holes at 1 in. and 2 in. deep. See Fig. 2.9.
Radial rim test, distance amplitude correction
Paragraph 2.9.3.2
Fig. 2.9
2.9.3.4 Alternate calibration standards may be used when authorized by the AAR WABL Com-
mittee. Wheel shop shall document and demonstrate the correlation between the 1/8-in.-diameter
flat-bottom hole and the proposed alternate standard.
2.9.3.5 Reference standards for the inspection of wheels shall be made from rim-treated wheel
steel, wrought or cast. Reference standard need not be the same AAR design as the wheels being
inspected.
"
"
FLANGE
TREAD
FRONT RIM
FILLET
2"
" 2"
2"
Typical Reference Standard for Rim Tread Ultrasonic Test
2/1/04
2/1/04 G-II39
SEGMENT 2.0 RP-631
2.9.4 Recalibration
Conduct ultrasonic calibration to ensure system conformance to required specifications. Check the
ultrasonic system and calibration of the instrument per documented procedures using calibration
standard when any of the following occurs:
Damage to any part of the ultrasonic system
Change in transducers, cables, and other accessories
Loss of power or equipment malfunction
Whenever ultrasonic instrumentation is first turned on
2.9.5 System Verification and Test Results Validation
2.9.5.1 Conduct ultrasonic calibration checks to ensure system conformance to required specifica-
tions.
2.9.5.2 System calibration must duplicate normal practices, including surface condition and cou-
plant, and be verified per documented procedures using calibration standard at least every 8 hours
of operation. If the results from system verification are outside of system tolerance, assessment of
previous inspections must be made and appropriate action taken. Action taken is to be supported
by wheel reinspection data.
2.9.5.3 Records shall be maintained of system calibration and system verification.
2.9.6 Scanning
2.9.6.1 Wheels shall be inspected radially from the tread surface.
2.9.6.2 One or more transducers shall be designed and located to give maximum volumetric cov-
erage of the rim cross-section radially.
2.9.6.3 Scanning speed shall permit detection of reference standards at calibration level for auto-
mated or semi-automated systems. Manual scanning techniques shall result in the detection of the
reference standards at all times.
2.9.7 Rejection
2.9.7.1 Any wheel with a flaw indication equal to or larger than 50% of the reference standard at
the estimated discontinuity depth shall be cause for rejection. All rejected wheels must be
scrapped.
2.9.7.2 Ultrasonic indications that result from wheel geometry or spurious electrical signals shall
not be valid cause for rejection.
2.9.8 Ultrasonic Nondestructive Testing Personnel Requirements
2.9.8.1 All personnel engaged in nondestructive testing will be qualified to NDT Level I according
to the qualification requirements as defined by the American Society for Nondestructive Testing
Recommended Practice SNT-TC-1A, latest edition.
2.9.8.2 All personnel conducting inspection setups and machinery setups will be trained and
qualified to meet the criteria for NDT Level II for nondestructive testing as defined by the Ameri-
can Society for Nondestructive Testing Recommended Practice SNT-TC-1A, latest edition.
2.9.8.3 Each wheel shop will employ the services of an individual who will be trained and quali-
fied to meet the criteria for NDT Level III for nondestructive testing as defined by the American
Society for Nondestructive Testing Recommended Practice SNT-TC-1A, latest edition.
2/1/04
G-II40 2/1/04
SEGMENT 2.0 RP-631
2.10 Ultrasonic Inspection of Wheels in Service
For detecting internal discontinuities in the rim of all freight car railroad wheels, radial ultrasonic
inspection may be performed using either the procedures shown below or an AAR-approved equiv-
alent.
2.10.1 Equipment
The equipment used must produce an indication from a rejectable flaw with a signal-to-noise ratio
of 15 dB or greater.
2.10.2 Calibration
2.10.2.1 Calibration shall be conducted using a flat, stainless steel (ASTM Grains size of 5, mini-
mum) reference standard with 1/8-in.-diameter flat-bottomed holes at 1/4-in.-depth increments
that completely span the range of testing depths. Distance amplitude correction (DAC) shall be
used. The couplant used must be the same as that used during testing.
2.10.2.2 Whenever a rejectable indication is found, the calibration must be immediately verified
against the reference standard defined above.
2.10.3 Rejection
2.10.3.1 Any wheel with a flaw indication equal to or larger than 50% of the reference standard
at the estimated discontinuity depth shall be cause for rejection as long as they are not within
3/8 in. of the tread surface.
2.10.3.2 Ultrasonic indications that result from wheel geometry or spurious electrical signals
shall not be valid cause for rejection. Ultrasonic indications within 3/8 in. of the tread surface are
not cause for concern and cannot be present in a signal when making a determination for rejection
(See Fig. 2.10).
2.10.4 Ultrasonic Nondestructive Testing Personnel Requirements
All personnel engaged in nondestructive testing will be qualified to NDT Level I according to the
qualification requirements as defined by the American Society for Nondestructive Testing Recom-
mended Practice SNT-TC-1A, latest edition.
2/1/04
2/1/04 G-II41
SEGMENT 2.0 RP-631
Ultrasonic Indication Depth Determination
Why Made Code 89
Paragraph 2.10.3
Fig. 2.10
0
50%
100%
0 0.5 1.0 1.5 2 2.5
3
8 "
0
50%
100%
0 0.5 1.0 1.5 2 2.5
3
8 "
Example of a typical signal from a condemnable
defect shown on a display where the ultrasonic
device was calibrated to show 1/8-in.-diameter
flat-bottomed hole reflections at 100% screen
height. The bottom scale is in inches and
represents the depth of the defect giving the
ultrasonic reflection.
In this case, the defect is deeper than 3/8 in. and
gives an indication of 58% of a 1/8-in.
flat-bottomed hole.
Example of a typical signal near a shelled or
spalled area on the tread (not always visible on the
surface). This defect is not condemnable since it
is present at a depth of 1/8 in. below the tread
surface.
The 56% peak is a multiple reflection from the
1/8-in.-deep shell or spall. Wheels cannot be
rejected where there is a screen indication present
at a depth of less than 3/8 in.
2/1/04
G-II42 2/1/04
SEGMENT 3.0 RP-632
3.0 GENERAL REQUIREMENTS AND INFORMATION
3.1 Wheel, Axle, and Bearing Failure Reports
3.1.1 Failed Axle Report
Reports of failed axles are to be submitted on the form shown in Fig. 4.72.
3.1.2 Failed Wheel Report
Reports of failed wheels are to be submitted on the form shown in Fig. 4.73.
3.1.3 Roller Bearing Hot Box and Shop Inspection Report
Reports of overheated roller bearings are to be submitted on form shown in Fig. 4.76 (as noted in
Paragraph 2.5.4 of this manual).
3.1.4 AAR Wheel Procurement Form
Reports of wheels purchased annually are to be submitted on form shown in Fig. 4.78.
3.2 Handling, Shipment, and Storage of Wheels and Axles
3.2.1 Wheel platforms and shops should be of sufficient size and arranged to facilitate the storing
of loose wheels according to kind, class, nominal diameter, car capacity, etc., and the storing of
axles according to type and nominal size.
3.2.2 Wheels and axles should be used in the same order as received so they do not become exces-
sively rusted in storage.
3.2.3 Storage tracks for serviceable wheels mounted with roller bearings in place must be
arranged so the flanges of one pair of wheels cannot strike the adjacent roller bearing housing or
the body of the adjacent axle. A suitable storage track arrangement is illustrated in Fig. 4.74.
3.2.4 Special wheel cars should be provided for shipping mounted wheels between wheel shops
and repair points. The AAR Open Top Loading Rules Manual illustrates approved methods of load-
ing. Such cars have proved to be more reliable than the use of blocking in preventing axles from
becoming damaged in transit.
3.2.5 When necessary to use an acetylene torch near axles, precautions should be taken to pre-
vent intense localized heating of any part of the axle, wheels, or any of the truck parts. These parts
should be adequately protected from the torch by asbestos board or heavy asbestos paper with pro-
vision for proper air space to prevent any excessive heating.
3.2.6 When handling pairs of mounted wheels, care should be taken that handling devices do not
damage the roller bearings.
2/1/04
2/1/04 G-II43
SEGMENT 3.0 RP-632
3.3 Wheel and Axle Specifications and Designs
3.3.1 The material specifications covering the various kinds of wheels and axles are published in
the AAR Manual of Standards and Recommended Practices, Section G. These may be purchased
from the Publications Department, Transportation Technology Center, Inc., P.O. Box 11130, 55500
DOT Road, Pueblo, CO 81001.. These specifications are as follows:
3.3.2 Wrought steel wheels are made to AAR Specification M-107. Cast steel wheels are made to
AAR Specifications M-208. Both specifications cover four classes of heat-treated wheels (A, B, C,
and L, designating the carbon content of the steel). Class A indicates a relatively low carbon steel
wheel; Class B, an intermediate carbon steel wheel; Class C, a relatively high carbon steel wheel;
and Class L, a carbon content lower than Class A. Heat treatment of steel wheels is by quenching
the rim only. The quenching is followed by tempering. Rim-quenched steel wheels formerly were
identified by stamping or casting the letter R following the class letter (except this was omitted
on steel wheels for locomotives). Since 1967, the R has been omitted on steel wheels.
3.3.3 The service for which the various classes of wrought and cast steel wheels are generally
intended is described in Specification M-107/208.
3.3.4 The information included in the markings applied to wheels and the location of such mark-
ings is shown in Fig. 4.73.
3.3.5 The tape size of wheels is paint-stencilled on the back plate with figures at least 1 in. high.
3.3.6 The markings to designate the class and the method of heat treatment are as follows:
Untreated wheels (Class U) were not marked for class prior to April 1, 1978. The marking require-
ments for wheel designs are shown in Fig. 4.73.
Specification
No.
Description
M-101 Axles, Carbon Steel, Heat Treated
This specification covers heat-treated axles (up to and including those 6 1/2-in.
nominal diameter at the center) and heat-treated axles of all sizes for locomotives
(material only), passenger cars, and freight cars.
M-107/208 Wheels, Carbon Steel
This specification covers wrought and cast-carbon steel wheels for locomotives and
cars.
U Class U, untreated (not produced for interchange service after March 31, 1989)
A Class A, rim treated
AE
a/

a/
Note: E designation is not used after 4/1/78.
Class A, entire wheel treated (wrought only)
B Class B, rim treated
BE
a/
Class B, entire wheel treated (wrought only)
C Class C, rim treated
CE
a/
Class C, entire wheel treated (wrought only)
L Class L, rim treated
LE
a/
Class L, entire wheel treated (wrought only)
2/1/04
G-II44 2/1/04
SEGMENT 3.0 RP-632
3.3.7 The following abbreviations have been used to designate the brand of manufacturer; how-
ever, in 1978, the letter W was added after all single-character brands (for wrought steel wheels)
(e.g., EW for Edgewater).
A
a/
a/
Note: No longer in production.
Armco
AW SCAW Metals Ltd. (South Africa)
B
a/
Bethlehem (BW)
C
a/
U.S. Steel Corp.Pittsburgh Plant (Carnegie) (CW)
DW Zelezarny Adratovny (Czech Republic)
E Edgewater (EW)
F ValdunesDunkerque Plant (France) (FW) (previously Creusot-Loire)
FM
a/
Fundiciones De Hierro y Acero (Mexico)
G
a/
U. S. Steel Corp.Gary Plant
J Sumithmo (Japan) (JW)
KW
b/
b/
Note: No longer AAR approved.
Kiockner (W. Germany)
L Lovere (Italy) (LW) (previously Italsider) (previously Term) MW Mafersa (Brazil)
P
a/
British SteelTempleborough and Icides Work (England)
PT ABB British Wheelsets
QW Construcciones y Auxiliar de Ferrocarriles (Spain)
RW SMR Rolling Stock Assemblies (Romania)
S Standard Steel Division (SW)
T ADtranz (previously British Steel)Trafford Park Works (England) (TW)
V ValdunesValenciennes Plant (France) (VW) (previously Usinor) (see F above)
WI Ministry of Railways (India)
Z
a/
Canadian Steel Wheel Division (ZW)
The following cast abbreviations are used on the plate to designate the brand of the manufacturer;
however, after about April 1,1978, two characters are used.
GC
a/
Griffin, Chicago Plant
GC Griffin, Columbus Plant
GL
a/
Griffin, Colton Plant
GY
a/
Griffin, St. Hyacinthe Plant GI Griffin, Kansas City Plant
GT Griffin, Winnipeg Plant
GB
a/
Griffin, Bensenville Plant GS Griffin, Bessemer Plant
GK Griffin, Keokuk Plant
SJ
a/
Abex, Johnstown Plant CZ IochpeMaxion, (Brazil)
SO ABC Rail (previously Abex), Calera Plant
C
a/
Abex Rail, Calera Plant
The letters C, S, or T directly precede the wheel serial number
for wheels manufactured prior to about April 1978
S
a/
Abex, St. Louis Plant
T
a/
Abex, Toledo Plant
2/1/04
2/1/04 G-II45
SEGMENT 3.0 RP-632
3.3.8 Axles were formerly identified by stamping on the wheel seat collar. However, current spec-
ifications require stamping on the end face for freight car roller bearing designs and stamping on
an undercut shoulder at the journal end for passenger car roller bearing designs. Stamping details
are shown in Fig. 4.9.
3.3.9 The loading rating of the designs of freight car axles, when used under freight cars, should
be as follows:
Cars with rail loads in excess of 65,750 lb per axle cannot be operated in unrestricted interchange.
However, they may be permitted under controlled conditions where special agreement has been
reached between participating railroads to so handle.
3.3.10 When axles corresponding to the passenger car axle design, as shown in paragraph 4.0,
are used on new cars in passenger car service, the load rating of the individual axles should be as
follows:
Table 3.1 Load ratings for freight car axles
AAR Axle
Designation
Journal Size
(in.)
Load Carried by Each Axle
(Two Four-Wheel Trucks)
(lb)
Maximum Weight on Rail of Car and
Load Based on Four Wheel Trucks
(lb)
E 6 11 52,500 220,000
F 6 1/2 12 68,750 286,000
G 7 12 76,000 315,000
K 6 1/2 9 68,750 286,000
L 6 8 52,500 220,000
M 7 9 76,000 315,000
Table 3.2 Load ratings for passenger car axles
AAR Axle
Designation
Journal Size
(in.)
Capacity for Axles for Normal Maximum Operating Speeds of
Up to and Including 85 mph 86 mph to 100 mph
D 5 1/2 10 36,000 lb 34,000 lb
E 6 11 45,000 lb 42,500 lb
F 6 1/2 12 54,000 lb 51,000 lb
2/1/04
G-II46 2/1/04
SEGMENT 4.0 RP-633
4.0 FIGURES FOR SEGMENTS 1., 2.0, AND 3.0
Dimensions of raised wheel seat roller bearing axles for freight cars
Rule 1.1.2
Fig. 4.1
ENLARGED SECTION SHOWING OPTIONAL
RADIUS WHEN USING CONTOUR GRINDER
* THE L DIMENSION NEED NOT BE CORRECTED FOR
LENGTH EACH TIME THE WHEEL SEATS ARE TURNED
ENLARGED VIEW SHOWING
CONDITION AT FILLET JOINING
BODY PORTION OF AXLE TO
INSIDE EDGE OF WHEEL SEAT.
MACHINE CHAMFER
TO 250 MICRONS MAX.
BREAK
SHARP
CORNER
W
B D
GH
I
J
K
E E
V
N
M
1
16"
U
1
16"
C 2"
3" R
NOTE: DIMENSION V DESIGNATES MINIMUM LENGTH OF FULL THREAD. DEPTH OF DRILLED
HOLE MUST EQUAL DIMENSION V PLUS
7
8 "
MAXIMUM.
MAXIMUM PERMISSIBLE VARIATION IN JOURNAL DIAMETER AT ANY PLACE MUST
NOT EXCEED .001 INCH AND THERE SHALL BE NO ABRUPT CHANGES OR STEPS
OVER THE LENGTH OF THE JOURNAL.
1
16"
R. MIN. TO
1
8 "
R. MAX
MATERIAL A.A.R. SPECIFICATION M101
AXLES SHALL BE MACHINED TO 250
MICRONS MAX. BETWEEN WHEEL SEATS
OVERALL LENGTH
STAMP
IDENTIFICATION MARKS
ON THIS SURFACE
Y
X
1 " R
+0"
1
16"
1 " R
+0"
1
16"
O
1
16"
TO OF JOURNAL
C
L
C
L
( *L) 47 "
+0"
"
STAMP
ON THIS SURFACE.
TU.N.C.2B TAP
3-HOLES COUNTERSINK
1
8 "
LARGER THAN BOLT DIA. T.
REMOVE SHARP CORNERS.
R
1
2
0
120
1
2
0
ON NEW AXLES MACHINE 3 INCH

RADIUS AT SPECIFIED DIMENSION L
FOR ANY WHEEL SEAT DIA.
WORN DIA
L*
2"
OVERSIZE DIA
NEW DIA
3"
J
0
+
1
8 "
Axle
Class
Journal
Size
Dimensions (in. unless otherwise noted)
B C D E G H I J K M N O R T
a/
a/
Dimension T is tap size
U V W X Y
D 5 1/2 10 5 1/2 1 3/4 7 5/8 3 Max 5.1915
Min 5.195
6 3/8 7 9/16 6 3/4 5 7/8 62 1/2 77 86 1/8 1 3/4 7/89 66 1 7/8 10 1/16 1 1/4 +0
1/4
2 8
E 6 11 5 15/16 1 13/16 7 5/8 3 Max 5.6915
Min 5.6905
7.032
7.030
8 1/4 7 5/16 6 7/16 62 1/2 78 88 1 15/16 18 66 1/8 2 10 15/16 1 1/4 +0
1/4
2 8
F 6 1/2 12 6 7/16 1 13/16 7 5/8 3 Max 6.1915
Min 6.1905
7.532
7.530
8 3/4 7 7/8 7 3/8 62 1/2 79 89 5/8 2 1/8 1 1/87 66 1/8 2 1/8 11 3/4 1 1/4 +0
1/4
2 8
G 7 12 5 15/16 2 5/16 7 5/8 3 Max 7.004
Min 7.003
8.002
8.000
9 1/2 8 9/16 8 62 1/2 79 89 1/4 2 5/16 1 1/47 67 1/8 2 1/4 11 1/16 5/8
1/8
4 15
K 6 1/2 9 4.853 3.397 7 5/8 3 Max 6.1915
Min 6.1905
7.532
7.530
8 3/4 7 7/8 7 3/8 62 1/2 79 87.156 2 1/8 1 1/87 69.294 2 1/8 8.931 0.250
0.020
10
L 6 8 4.457 3.293 7 5/8 3 Max 5.6915
Min 5.6905
7.032
7.030
8 1/4 7.5/16 6 7/16 62 1/2 78 85.500 1 15/16 18 69.086 2 8.207
M 7 9 4.750 3.500 7 5/8 3 Max 6.5040
Min 6.5030
7.532
7.530
9 1/2 8 9/16 8 62 1/2 79 87.500 2 1/8 1 1/87 69.500 2 1/8 9.000
Notes:
1. Dimension I tolerance is 0.015.
2. Maximum allowable runout between G and I is .008 in. total dial indicator.
4. For 7 in. 12 in. journals, end chamfer is 4 15 ft 5/8 in. 1/8 in.
5. Required for press fit of roller bearing backing ring where the H diameter is
toleranced. Finish to 125 microinch maximum when toleranced.
6. Dimension W cannot exceed the tolerance limits of the gauge shown for
Fig. 5.26.
7. Runout on journal surface G, when rotated on centers, must not exceed .015 in.
total dial indicator.
8. Dimensions B and N are considered engineering data for truck design and do
not necessarily agree with axle manufacturing tolerances.
9. Journal finish must not exceed 63 microinch, if ground or turned only. If turned
and rolled, the turned finish must not exceed 125 microinch and the rolled finish
must not exceed 16 microinch.
CHECK LOCATION WITH
GAUGE SHOWN IN
FIG. 5.12
2/1/04
2/1/04 G-II47
SEGMENT 4.0 RP-633
Dimensions of raised wheel seat roller bearing axles for freight cars
Rule 1.1.2
Fig. 4.2
Axle
Class
Journal
Size
Dimensions, in.
A B1 B2 C D DI DJ E F G H I II J K L M N O P R T
a/
a/
U V
D 5 1/2 10 1/2 4 1/16 5 1/2 1 3/4 8 1/8 1/2 23/32 3 5 1/16 Max 5.1915
Min 5.1905
6 3/8 7 7 3/8 6 3/4 5 7/8 45 1/4 62 1/2 77 86 1/8 4 9/16 1 3/4 7/89 66 1 7/8
E 6 11 1/2 4 1/2 5 5/16 1
13/16
8 5/8 1 3/4 3/4 3 5 9/16 Max 5.6915
Min 5.6905
7 7 5/8 8 7 3/16 6 7/16 41 3/4 62 1/2 78 88 5 11 5/16 18 66 1/8 2
F 6 1/2 12 1/2 4 13/16 6 7/16 11 3/16 8 5/8 1 3/4 3/4 3 6 1/16 Max 6.1915
Min 6.1905
7 1/2 8 1/8 8 1/2 7 13/16 7 3/8 41 3/4 62 1/2 79 89 5/8 5 5/16 2 1/8 1 1/87 66 1/8 2 1/8
BREAK SHARP
CORNER
STAMP
IDENTIFICATION
MARKS ON
THIS SURFACE
BREAK
SHARP
CORNER
B2
D
GH
I
J
K
E E
V
O
1
16"
N
L
C
0
.
0
0
5
"
1"
R
NOTE: ROLLER BEARING AXLES, WHEN FINISHED ON LATHE CENTERS, SHALL
HAVE ENDS RECENTERED PRIOR TO GRINDING OR ROLLING OF JOURNALS.
TAPER OF G DIAMETER MUST NOT
EXCEED .001 OVER LENGTH OF JOURNAL.
ENLARGED SECTION SHOWING OPTIONAL
RADIUS WHEN USING CONTOUR GRINDER.
NOTE: DIMENSION V DESIGNATES MINIMUM LENGTH
OF FULL THREAD. DEPTH OF DRILLED HOLE
MUST EQUAL DIMENSION V PLUS
7
8 "
MAXIMUM.
AS FORGED BETWEEN
WHEEL SEATS.
OVERALL LENGTH
FOR AXLE CENTER SEE
SEPARATE PLATE.
ALTERNATE MACHINING
OF END OF AXLE.
A
1
16"
R MIN TO
1
8 "
R MAX
P
F
B1
P
G
DI
DJ
I

I
" R
TO OF JOURNAL
C
L
C
L
1 "
+0"
1
16"
1 "
+0"
1
16"
U
+0"
1
16"
1
8 "
R
"
3
64"
M
+0"
1
16"
T U.N.C. 2B TAP
3-HOLES COUNTERSINK
1
8 "
LARGER THAN BOLT DIA.
T REMOVE
SHARP CORNERS.
R
1
2
0
120
STAMP
ON THIS SURFACE.
1
2
0
CHECK LOCATION WITH

GAUGE SHOWN IN
FIG. 5.12
Notes:
1. Dimension I tolerance is 0.015.
2. Maximum allowable runout between G and H is .006 in. total dial indicator.
4. When required for press fit of roller bearing backing ring, the H diameter is
toleranced.
5. Check converted axles with gauge shown in Fig. 5.26.
6. Runout on journal surface G, when rotated on centers, must not exceed
.015 in. total dial indicator.
7. When black collar axles are being machined, the end chamfer shall be
machined to the tolerances shown in Fig. 4.1.
8. Journal finish must not exceed 63 microinch, if turned or ground only. If turned
and rolled, the turned finish must not exceed 125 microinch and the rolled
finish must not exceed 16 microinch.
2/1/04
G-II48 2/1/04
SEGMENT 4.0 RP-633
Journal dimensions for raised wheel seat roller bearing passenger car axles
Rule 1.1.2
Fig. 4.3
Axle
Class
Journal
Size
Dimensions, in.
A B1 B2 C D F G H I
a/
a/
Dimension I tolerance is 0.015.
L M N O P Q R S T
b/
b/
U
D 5 1/2 10 1 1/16 3 11/16 4 7/8 2 1/8 7 7/8 5 7/16 Max 5.504
Min 5.503
6.703
6.701
7 9/16 47 1/4 63 77 86 1/2 4 3/4 1 1/2 1 1/2 4 1/2 3/410 67 1/4
E 6 11 15/16 4 3/16 5 3/8 2 3/8 7 5/8 5 15/16 Max 6.004
Min 6.003
7.250
7.249
8 1/4 47 1/4 62 1/2 78 88 1/4 5 1/8 1 1/2 1 3/4 4 1/2 7/89 67 1/4
F 6 1/2 12 1 1/8 4 3/4 5 15/16 2 7/16 7 1/2 6 7/16 Max 6.504
Min 6.5003
7.906
7.905
8 3/4 47 1/4 62 1/4 79 90 3/4 5 7/8 1 1/2 1 15/16 4 1/2 7/89 67 1/4
DO NOT STAMP
IDENTIFICATION
ON THIS SURFACE
RADIUS Q AND 1" RADIUS BACK
OF DUST GUARD SEAT ARE
REQUIRED AS SHOWN TO
ACCOMMODATE ALL TYPES
OF ROLLER BEARINGS
THAT MAY BE APPLIED
TO THESE AXLES
ROLLER BEARING AXLES, WHEN FINISHED
ON LATHE CENTERS, SHALL HAVE ENDS
RECENTERED PRIOR TO GRINDING OR
ROLLING OF JOURNALS
T U.N.C. 2B TAP
3-HOLES COUNTERSINK 1/8"
LARGER THAN BOLT DIAMETER
BOLT DIAMETER T REMOVE
SHARP CORNERS
BREAK SHARP
CORNER.
B2 D
G
H
I
C
R
0
.
0
0
5
"
MAXIMUM PERMISSIBLE VARIATION IN
JOURNAL DIAMETER AT ANY PLACE MUST
NOT EXCEED .001 INCH AND THERE SHALL
BE NO ABRUPT CHANGES OR STEPS OVER
THE LENGTH OF THE JOURNAL
AXLES SHALL BE MACHINED
TO 250 MICRONS MAX
BETWEEN WHEEL SEATS
POLISH FREE FROM
TOOL MARKS & SCRATCHES
A
P
F
B1
1
2
0
1
2
0
1
2
0
STAMP IDENTIFICATION
MARKS HERE
S
1 "
FOR AXLE
CENTER
SEE
SEPARATE
PLATE.
N
TO OF JOURNAL
C
L
C
L
OVERALL LENGTH
O
1
32"
M
+ 0"

1
32"
L
+ 0"
"
U
+ 0"

1
32"
+0"
1
16"
1"
Q
+0"
1
16"
1
8 "
R
2/1/04
2/1/04 G-II49
SEGMENT 4.0 RP-633
Shop limits for roller bearing axles
Rules 1.1.2 and 1.2.1
Fig. 4.4
ROLLER BEARING (BC) BLACK COLLAR ROLLER BEARING (RWS) RAISED WHEEL SEAT
SEE NOTE #4
D
GHK
U
A
B
IG H
A
I
1 " R
1
16"
R
1
16"
R
1 " R " R
Axle
Class
Journal
Size
A B D I K U
Minimum Minimum
Black Collar,
Freight Car,
Minimum
Raised Wheel Seat
Freight or Passenger
Cars, Minimum
D 5 1/2 10 11 13/16 19 15/16 19 7/16 6 3/4 7 3/16 5 3/4 65 7/8
E 6 11 12 3/4 21 3/8 20 3/8 7 3/8 7 7/8 6 5/16 66
F 6 1/2 12 13 9/16 22 3/16 21 3/16 7 7/8 8 3/8 6 3/4 66
G 7 12 13 3/8 21 9 1/4 7 7/8 67
K 6 1/2 9 12.238 19.953 8 3/8 6 3/4 69.169
Notes:
1. See paragraph 5.0 for wheel seat, journal, dust guard, and seat and
fillet gauges.
2. A smooth cutting file or other suitable tool should be used to break
corners where 1/16 in. radius is shown.
3. Secondhand black collar axles, when remachined, may not exceed
Dimension A by more than 1/4 in.
4. See Fig. 4.5 for the method of measuring roller bearing journals,
Dimension G.
5. Maximum allowable runout between G and H is .008 in. total dial
indicator.
6. Maximum allowable runout between G and I is .015 in. total dial
indicator.
2/1/04
G-II50 2/1/04
SEGMENT 4.0 RP-633
Method of measuring roller bearing journals
Rules 1.1.2, 1.2.4, 1.2.8, 1.8.2.2, and 1.2.7.2 and Paragraph 2.5.4.7
(For gauge, see Fig. 5.18)
Fig. 4.5
A
B
C
D
BEARING SEATS
A
GROOVE CAUSED BY
SEAL WEAR RING
AREA WHERE UPSETS OCCUR
D
BEARING SEAT AREAS
Dial or digital snap gauge must be rotated around the
journal diameter at least 180 within the bearing seat
locations to obtain the maximum and minimum journal
diameters. The average diameter of each bearing seat
must be within tolerances. Care must be taken when using
temperature compensating snap gauges that rotation
speed does not create sufficient heat, caused by friction, to
affect the readings. There shall be no abrupt changes or
steps over the length of the journal, including the tapered
end, except that journal grooving from the inboard seal
wear ring is permissible when repaired in accordance with
Rule 1.2.8.
Journal
Acceptance Toler-
ance for Secondhand
Journal Diameter
Bearing Seat Locations (in.)
(see Fig. 5.18 for location gauge)
Class Size Maximum Minimum A B C D
Freight Car Axles
D 51/2 10 5.1920 5.1905 2 5/8 4 57/64 6 8 21/32
E 6 11 5.6920 5.6905 2 7/8 5 13/64 6 9/16 9 5/16
F 6 1/2 12 6.1920 6.1905 2 15/16 5 45/64 7 1/16 10 3/8
G 7 12 7.0045 7.003 2 3/8 5 5/16 6 1/2 9 13/16
K 6 1/2 9 6.1915 6.1905 1 53/64 4 19/32 5 8 5/16
Amtrak Axles
D 5 1/2 10 5.5045 5.503 1 1/2 4 9/16 5 1/8 8 9/16
E 6 11 6.0045 6.003 2 5 1/16 5 3/8 9 1/16
F 6 1/2 12 6.5045 6.503 2 3/8 5 5/16 6 1/2 9 13/16
JOURNAL GROOVING FROM INBOARD SEAL WEAR
RING
Rule 1.2.8 gives the accept/reject criteria and process for
repairing grooves in journals caused by inboard seal wear
rings.
MEASURING FOR UPSET JOURNAL ENDS
Dial or digital snap gauge must be rotated 180 around the
area where upsets occur. In order for a journal to be
acceptable, the diameter in the area where upsets occur
must never exceed 0.003 in. above maximum tolerance in
the table above, but may be below the minimum tolerance.
Upset ends over 0.003 in. may be corrected per Rule 1.1.5.
2/1/04
2/1/04 G-II51
SEGMENT 4.0 RP-633
Journal qualification example
Rule 1.2.4
Fig. 4.6
WHEEL FLANGE MARKS
(.14 sq. in.)
JOURNAL SURFACE
.500
.062 (MAX) SCALE: 2X
SECTION AA
NOTE:
FEATURES SHOWN ON THIS JOURNAL ARE EXAMPLES FOR CALCULATING THE
TOTAL COMBINED AREA OF ALL DEPRESSIONS IN JOURNAL SEATING AREAS.
(THE TOTAL COMBINED AREA OF ALL FEATURES SHALL NOT EXCEED 1 sq. in. PER CONE SEAT.)
REPAIRED GALL: RADIUS OF THE DEPRESSIONS MUST BE GREATER THAN OR EQUAL
TO
1
8 "
TO MINIMIZE STRESS CONCENTRATION. (SMOOTHLY BLENDED INTO THE CONTOUR
OF THE JOURNAL SURFACE) (.375 sq. in.)
0.955 sq. in. 2.96 sq. in.
.21 sq. in. .125 (MAX)
FULL JOURNAL LENGTH SCORE
.250
.750
.125 (MAX)
.375 sq. in.
.375 sq. in.
.500
A
A
1.500
1.7"
2.7 in.
BEARING SEATS
2/1/04
G-II52 2/1/04
SEGMENT 4.0 RP-633
Gauge for checking axle fillet of roller bearing axles
(Also see Fig. 5.18)
Rules 1.1.2, 1.2.4, and 1.8.2.2
Fig. 4.7
1 "
*
1
.
5
"

R +
.0
0
0
.0
0
5
2 "
AXLE FILLET GAGE
MATERIAL: " STEEL
1
16"
5 " (MIN)
NOTE: GAUGE TO BE RELIEVED
1
16"
2 " AS SHOWN
*WEAR TOLERANCE TO BE +0.00
1
64"
FOR THIS DIMENSION ONLY.
3
8
"
0.005" MAX
Note: The journal fillet area of a roller bearing axle is critical. To ensure proper fit and proper seating of the backing ring on the
axle fillet, the journal fillet gauge must be used to check the fillet radius. If a 0.005-in. feeler gauge can be inserted more than
8 in. down from the dust guard seat at all points around the periphery, the axle fillet must be corrected.
2/1/04
2/1/04 G-II53
SEGMENT 4.0 RP-633
Axle centers
Rules 1.1.2 and 1.1.4
Fig. 4.8
FINISHED DIMENSIONS
AXLE SIZES
E - 6" 11"
F - 6 1/2 " 12"
G- 7" 12" FREIGHT ROLLER
BEARINGS
PASSENGER
ROLLER
BEARINGS
60
60
1
15
16"
MIN.
2" MAX.
1
/
8
"
+
1
/
3
2
"
0
"
AXLE SIZES
D- 5 " x 10"
1"
1
8 "
1
5
8 "
MAX.
1
9
16"
MIN.
60
60
1"
1
8 "
7
16"
+
1
16"
0"
1

1
8
"

1
1
6
"
7
16"
+
1
16"
0"
1

1
8
"

1
1
6
"
1
8
"

+

1
3
2 "

0
"
1
5
8 "

1
8 "
1

"

1
1
6
"
7
16"
+
1
16"
0"
1
5
8 "

1
8 "
1

"

1
1
6
"
7
16"
+
1
16"
0"
FOR AXLE WITH
SPLINE BUSHING
1
"
1 "
BREAK SHARP
CORNER
2.000"
+ .000"
.001" REAM
2

3
8
"

1
3
2
"
1
8 "
R
3

3
8
"
2/1/04
G-II54 2/1/04
SEGMENT 4.0 RP-633
Note 1. Laboratory acceptance stampfor use by purchaser to signify acceptance of axles so marked prior to shipment
by producer.
Note 2. Serial number when specified (required after 1980)
Note 3. Manufacturer name or brand:
BF Bumar Fablok S.A. (Poland)
BS
a/
Bethlehem Steel Corporation, Johnston Plant
CAF Construcciones y Auxiliar de Ferrocarriles (Spain)
CB
a/
Cobrasma (Brazil)
CF Valdunes, Dunkerque Plant (France) (previously Creusot-Loire)
CHT Norinco-Jinxi (China)
DDAP Dneproderzhinsk Axles (Ukraine)
DSS JSC DneproSpetsStal (Ukraine)
HM Huta Gliwice [previously Huta 1 Maya (Poland)]
JAW Standard Forged ProductsJohnston
KW
a/
Kiockner (W. Germany)
L Lucchini [previously Lovere (Italy)] (previously Italsider) (previously Terni)
LCKZ LugCentroKuZ (Ukraine)
LP Lucchini Poland (Poland)
MK
a/
Makrotek (Mexico)
MRF Standard Forged ProductsMcKees Rocks Forgings
MW
a/
Mafersa (Brazil)
SCOT Scot Forge
SFC or SF
a/
Standard Forgings
SSD Standard Steel Division
SMI Sumitomo Metal Industries Ltd. (Japan)
SPT
a/
British Steel, Templeborough & Ickles Works (England)
SW SWASAP (South Africa)Dorbyl
T
a/
British Steel, Trafford Park Works (England)
THM Taiyuan Heavy Machinery (PRC)
a/
No longer in production.
AAR standard axle markings (page 1 of 2)
Rules 1.1.2, 1.1.12, 1.1.13, and 1.2.7.5 and Paragraphs 2.1.2.5 and 3.3.8
Fig. 4.9
NOTE 7
NOTE 6
NOTE 3
NOTE 5
NOTE 2
NOTE 1
NOTE 4
11 66
USS H
6
6

A
0
0
1 0
0
0
0
0
T
F
L
NOTE 11
NOTE 12
NOTE 13
NOTE 9
NOTE 8
V1BW
5-89 Y-AT
X-BN-H
8-85
ROLLER BEARING
FREIGHT CARS
ONLY
NOTE 7 NOTE 6
NOTE 3
NOTE 5
NOTE 2
NOTE 1
NOTE 4
11 66 66 A001 F
L T 00000 USS H
11 66
USS H
NOTE 8
NOTE 9
ROLLER BEARING
PASSENGER CARS
ONLY
CIRCUMFERENTIAL DEVELOPMENT
OF AXLE END
2/1/04
2/1/04 G-II55
SEGMENT 4.0 RP-633
TW plus
a/
Letter T and a number in a diamond. Hawker Siddeley Canada Inc., Trenton Works
UF Ural Forge (Russia)
USS-F
a/
United States Steel Corporation Fairfield Works
USS-G
a/
United States Steel Corporation Gary Works
USS-H
a/
United States Steel Corporation, Homestead Works
V Valdunes, Valenciennes Plant (France) (previously Creusot-Loire)
WAP Ministry of Railways (India)
ZB Zelezarny A Dratovny (Czech Republic)
Note 4. Month and year made
Note 5. Letter T stamped adjacent to the heat number or the serial number. Axle has been ultrasonically inspected by
the manufacturer (stamping not required after 1980).
Note 6. Grade of axle:
U Untreated
G Quenched and tempered
F Double normalized and tempered
H Normalized, quenched, and tempered
Note 7. Heat number
Note: Stamping mounting information on axles in these locations was
discontinued October 1, 1972.
Note 8. Conversion date
Note 9. X (wheel shop symbol)
Note 10. Converted axles must be stamped with the conversion date (Note 8. location) and the letter X followed by the
wheel shop symbol (Note 9. location). Manufacturers pertinent information must be reapplied to the end of axle,
if available (Note 1. through Note 7.)
Note 11. Axles repaired by Specification M-967 processes must be stamped with the letter V followed by one or two
sequential numbers identifying the journals repaired and by the AAR-assigned identifying marks (Note 11
location). Sequential odd numbers will be used to identify journal repairs and the end of axle on which markings
are applied; sequential even numbers will be used for the other end. For example, V1BW, V23BRX means
journal at marking end of axle repaired and followed later by both journals being repaired with journal at marking
end being repaired a second time.
Note 12. Month and year repaired
Note 13. Shops that finish-machine new axles, excluding wheel seats, will show the letter Y followed by the wheel shop
symbol (Note 12 location). Axle manufacturers that finish-machine axles will use the brand shown in Note 3
above.
General Notes:
All marks will be deeply and legibly stamped with characters not less than 1/4 in. high.
Manufacturer must finish turn one end of the axle for stamping.
All elevations or irregularities should be filed or ground after stamping.
The above are the minimum marking requirements, but the locations or individual items may vary from those
illustrated.
For marking Amtrak inboard roller bearing passenger car axles, see Fig. 4.13.
Markings illustrated in the figure for roller bearing axles for freight cars show markings that may be on either new
or old axles, depending on requirements in effect at the time the markings were applied.
a/
No longer in production.
AAR standard axle markings (page 2 of 2)
Rules 1.1.2, 1.1.12, 1.1.13, and 1.2.7.5 and Paragraphs 2.1.2.5 and 3.3.8
Fig. 4.9
2/1/04
G-II56 2/1/04
SEGMENT 4.0 RP-633
Typical burnishing rollers for platted journals
Rule 1.2.7.3
Fig. 4.10
ROLLER BEARINGS
OPPOSED ROLLER TYPE
0- 49'
3
32"
R .010"
11
16"
R .010"
1
1
8 " 1
3
16"

3

3
8
"

5

5
8
"

D
I
A
11
16"
R .010"
3
32"
R .010"
TOOL POST TYPE
WITH PIN AND BUSHING

4
"

D
I
A
.
1"
2/1/04
2/1/04 G-II57
SEGMENT 4.0 RP-633
Check for bent axlealternate method
Rules 1.1.2 and 1.2.2
Fig. 4.11
Operation:
1. Remove protective covers from rollers.
2. Place the axle in the fixture so that rollers support the journal surface at a point as close as possible to the fillet.
3. Attach the dial indicator to the stand and set it up to record readings about 1/4 in. to 1/2 in. from the end of the journal.
Plunger of indicator should be normal to the longitudinal centerline of the axle.
4. Rotate the axle one or two turns to locate the low or minimum reading and set the dial indicator to zero at this point.
5. Continue to rotate the axle in the same direction, noting indicator variation. At the end of each revolution, the dial will
return to zero if it has been set up properly.
6. A maximum runout of 0.010-in. total indicator reading is allowed.
2/1/04
G-II58 2/1/04
SEGMENT 4.0 RP-633
Table of new and limiting dimensions for inboard roller bearing axle
Rule 1.1.2
Fig. 4.12
OVERALL
O
U
H
K J G I
Notes:
1. Oversize axles may be 0.030 in. larger than shown under Dimension I.
2. Dimension O may be +1/32 in. or 3/63 in.
3. Other axle dimensions are to be the same as for the inboard bearing axle, Fig. 4.13
Journal
Size (in.)
Road Limits (in.)
a/
When Less Than
a/
Requires the removal of the axle from service.
Shop Limits (in.)
b/
When Less Than
b/
Axles must not be applied in passenger service or under foreign equipment if not within these limits.
New Dimensions (in.)
c/
c/
See Note 1 and Note 2.
I K I U O K I J K G H O U
6 1/2 12 5 7/8 6 1/8 5 7/8 35 7/16 70 61/64 6 1/8 6 1/8 6 5/8 6 1/4 6.1915
6.1905
6.502
6.500
71 35 1/2
2/1/04
2/1/04 G-II59
SEGMENT 4.0 RP-633
Journal dimensions for Amtrak inboard roller bearing passenger car axles
Rule 1.1.2
Fig. 4.13
END FACES MUST
BE SQUARE WITH
O.D. (TYP)
METHOD OF COLD ROLLING RELIEF GROOVES
NOTES:
1. MATERIAL AAR, M-101 GRADE F, THE AXLE OTHERWISE MUST
BE IN COMPLIANCE WITH AAR SPECIFICATION M-101, LATEST
REVISION.
2. ROUGH MACHINED AXLE TO BE SUB CRITICALLY QUENCHED
FROM 1000 TO 1050F IN WATER. ALLOW .187" OVER FINISHED
DIAMETERS. RELIEF GROOVES TO BE MACHINED AND COLD
ROLLED AFTER SUB CRITICAL QUENCHING.
3. FINISH MARKS REMOVED IN 1982 REVISION.
LABORATORY ACCEPTANCE, MANUFACTURERS NAME OR BRAND,
MONTH & YEAR, HEAT NUMBER, SERIAL NUMBER, GRADE OF AXLE
AND PART NUMBER TO BE STAMPED ON ONE END OF AXLE TUBE
BY MANUFACTURER & TRANSFERED TO FINISH AXLE IN THE
PRESENCE OF RAILROAD COMPANY INSPECTOR UNLESS, WAIVED
BY RAILROAD COMPANY.
DATE OF APPLICATION AND PLACE WHERE MOUNTED TO BE
STAMPED ON OPPOSITE END OF AXLE BY BUILDER OR RAILROAD
COMPANY.
BEARING SEAT TO BE UNIFORM DIAMETER
THROUGHOUT. TAPER NOT TO EXCEED
.001 PER FOOT ON DIAMETER. (TYPICAL)
WHEEL SEAT
(TYPICAL)
.88 R TYP
.03 TYP
.38 TYP
7.00
17.75
1.25
5.90
C
.015
6.25 DIA.
35.50
.015
15.95
46.00 JOURNAL CENTERS REF
71.00
+.052
.046
B
3.00 R
6.502
6.500
DIA.
6.1915
6.1905
DIA.
6.135
6.125
DIA.
6.6260
6.6240
DIA.
DIA. 6.31
.015
DIA. 5.81
.015
DIA. 5.69
.015
A
SYMMETRICAL ABOUT
FINISHED AXLE
AXLE
C
L
C
L
.44
+.06
.00
DIA.
DETAIL A
60
1.63 DIA.
.13
+.03
.00
2.00
1.94
DIA.
.06 1.50
DETAIL B
.078
.19 R
5
5.90 REF. .265
.50 R
.19 .19
COLD ROLL RELIEF GROOVES OVER
REGION SHOWN WITH ROLLER HAVING
CONTOUR OF .19 RADIUS. USE 1200 POUNDS
ROLLER PRESSURE. START ROLLING AT
THESE POINTS. ROLL DOWN GROOVE
AND OVERLAP AT BOTTOM.
.19
.19
DETAIL C
5.81 DIA.
REF.
.44
.88 R
.25 R
+.00
.05
LABORATORY
ACCEPTANCE
STAMP
F
.
GRADE OF AXLE
F FOR
CHEMISTRY ONLY
MFG. NAME OR
BRAND
MONTH
& YEAR
STAMPING ONE END OF AXLE
PART NO.
HEAT NO.
4.00 DIA.
MO. & YR. WHEELS
MOUNTED
4.00 DIA.
.25
STAMPING OTHER END OF AXLE
WHERE MOUNTED
2/1/04
G-II60 2/1/04
SEGMENT 4.0 RP-633
Recommended procedure for checking magnetic particle solution for concentration and contamination
Rules 1.1.8 and 1.7.2
Fig. 4.14
100
mL
50
25
20
15
10
8
6
4
3
2
15
10
5
FILL TO 100 mL MARK
DEPTH OF SETTLING
INDICATES BATH STRENGTH
1. Solution should be checked weekly and immediately after each recharging.
2. Solution should be agitated for at least 20 minutes and run through the hose and nozzle for 30 seconds. Then obtain a
sample per the centrifuge tube above. Allow the bath to settle. Depth of settling should be .1 mL to .3 mL.
Note: Contaminates should not be considered as part of the solution but are to be noted when checks are made.
Concentration and contamination for bath solution can be readily observed when the settling tube is exposed to
ultraviolet light.
3. When the bath solution becomes contaminated to the extent that the detectability test in Rule 1.1.8 cannot be met, the
bath solution must be changed.
4. The concentration and contamination readings obtained are to be shown on record per Rule 1.7.2 and Fig. 4.71.
2/1/04
2/1/04 G-II61
SEGMENT 4.0 RP-633
Recommended method for checking boring mill
Rule 1.3.2 and Paragraph 2.2.2
Fig. 4.15
SEE INSET -
GAGE END OFFSET
RADIAL ERROR
WELDED
TO TOOL SHANK
PLANE ERROR
BORING BAR
Maximum total dial indicator runout 0.008 in.
Position of indicating gauge in checking for concentricity of wheel bore
Maximum total dial indicator runout 0.015 in.
Position of indicating gauge in checking for diagonal bore
2/1/04
G-II62 2/1/04
SEGMENT 4.0 RP-633
Set-up for grinding boring mill chuck jaws
Fig. 4.16
2/1/04
2/1/04 G-II63
SEGMENT 4.0 RP-633
Back hub entry chamfer
Rule 1.3.5
Fig. 4.17
A 1/8-in. radius may be provided in lieu of the chamfer as shown.
2/1/04
G-II64 2/1/04
SEGMENT 4.0 RP-633
List of wheels intended for freight and passenger car service
Rule 1.4.7
Fig. 4.18
Wheel Design
Designation
Rim Type
Capacity
(ton)
Maximum
Finish Bore
(in.)
Minimum
Hub Wall Thickness
(in.) Wrought Cast
List of Wheels Intended for Freight Car Service
A-28 CA-28 MW 100 8 7/8 1 1/8
CB-28 1W (Not over 24,375 lb
per wheel)
8 3/8 1 1/8
CD-28 1W 8 3/8 1 1/8
E-28 CE-28 1W 8 3/8 1 1/8
A-30 CA-30 MW 100 8 7/8 1 1/8
AX-30 CAX-30 MW 50 7 11/16 1
A-33 CA-33 1W 50 7 11/16 1
G-33 CG-33 MW 50 to 100 9 1/4 1 1/8
J-33 CJ-33 1W 50 to 70 8 3/8 1 1/8
K-33 CK-33 2W 50 7 11/16 1
M-33 CM-33 2W 50 to 70 8 3/8 1 1/8
N-33 CN-33 MW 50 7 11/16 1
P-33 CP-33 MW 50 to 100 9 5/8 1 1/8
R-33 CR-33 MW 70 8 3/8 1 1/8
H-36 CH-36 1W 100 8 7/8 1 1/8
J-36 CJ-36 2W 100 8 7/8 1 1/8
K-36 CK-36 MW 100 8 7/8 1 1/8
B-38 CB-38 1W 125 9 5/8 1 1/4
C-38 CC-38 2W 125 9 5/8 1 1/4
D-38 CD-38 MW 125 9 5/8 1 1/4
List of Wheels Intended for Passenger Car Service
A-32 CA-32 MW 6 1/8 1 1/16
A-34 CA-34 MW 9 1/4 11 /8
A-36 CA-36 MW 7 3/4 1
B-36 CB-36 MW 8 1/2 1 1/8
C-33 CC-33 MW (Not over 22,125 lb
per wheel)
7 3/4 1
D-36 CD-36 MW 8 1/2 1 1/8
E-.36 CE-36 MW 10 1/4 1 3/8
G-36 CG-36 MW 8 1/2 1 1/8
M-36 CM-36 MW (See the Manual of Standards and Recommended
Practices, Section G, Standard S-657, for other data)
2/1/04
2/1/04 G-II65
SEGMENT 4.0 RP-633
Wheel mounting pressures, tons
Rules 1.3.4 and 1.4.1 and Paragraph 2.3.4
Fig. 4.19
Table 4.1 Mounting pressures
Class of Axle Journal Size (in.)
Steel Wheels
Min Max
D 5 1/2 10 (50-ton wheel) 80 130
D 5 1/2 10 (70- ton wheel) 85 150
E and L 6 11 85 150
F and K 6 1/2 12, 6 1/2 9 90 160
G and M 7 12 100 170
F Passenger Car 6 1/2 12 inboard bearing axle 70 120
Table 4.2 Mounting pressures for WC-10 wheel mounting compounds only
Class of Axle Journal Size (in.)
Steel Wheels
Min Max
D 5 1/2 10 92 150
E and L 6 11 92 150
F and K 6 1/2 12, 6 1/2 9 98 160
G and M 7 12 108 170
F Passenger Car 6 1/2 12 inboard bearing axle 70 120
Note: Mounting pressures outside the limits shown above indicate improper interference fit or improper
lubricant ,and corrections must be made.
2/1/04
G-II66 2/1/04
SEGMENT 4.0 RP-633
Identification of wheel fit pressure diagram
Rule 1.4.1
Fig. 4.20
TYPE OF WHEEL AND NOMINAL WHEEL SEAT
DIAMETER TO BE SHOWN FOR EACH RECORD
OR AT LEAST WHEN THERE IS A CHANGE IN
THE TYPE OR THE NOMINAL WHEEL SEAT
DIAMETER OF THE WHEELS BEING MOUNTED.
OPENING OR WINDOW IN GAGE CASE
AVAILABLE FOR WHEEL RECORD
IDENTIFYING WHEEL NUMBER
5"
4 5 6 7 8 1
RECORD OF EACH WHEEL MOUNTED TO BE INDICATED ON
PRESSURE DIAGRAM CHART, SEE RULE 1E1.
THE SIZE AND LOCATION OF THE OPENING OR WINDOW IN THE
GAGE CASE WILL VARY FOR DIFFERENT STYLES OF GAGES.
THE TYPE OF WHEEL AND THE NOMINAL WHEEL SEAT DIAMETER
MAY BE DESIGNATED BY SYMBOLS PROVIDED THEIR USE WILL
NOT CAUSE CONFUSION.
SPACE FOR MARKING
MISFIT MOUNTINGS.
200
180
160
140
120
100
80
60
40
20
0
2/1/04
2/1/04 G-II67
SEGMENT 4.0 RP-633
Constructing and Using a Typical Wheel Mounting Template
1. Using a current wheel mounting chart, measure the distance A from the origin of the mounting diagram to the horizontal
return line. This represents the width of interference fit between the wheel and the axle.
2. Calculate the distance B. (B = .25 A)
3. Draw the following diagram on a piece of mylar or other suitable dear plastic. Use a black pen for the coordinates and
return line (solid lines) and a pencil for all other lines (dashed).
4. Using a red pen, draw in the dashed lines shown in the figure below. Draw in the dash-dotted line with a green pen and
the dotted lines with a blue pen.
Constructing and using a typical wheel mounting template (page 1 of 2)
Paragraph 2.3.5
Fig. 4.21
0
A
B
B
30
90 160
0 30
A
B
B
Minimum
Tonnage
Maximum
Tonnage
B
0 30 Minimum
Tonnage
Maximum
Tonnage
75% fit
2/1/04
G-II68 2/1/04
SEGMENT 4.0 RP-633
(
An example of an ideal mount
Fig. 4.22
Example of an acceptable amount
Fig. 4.23
5. Erase all pencil lines.
Constructing and using a typical wheel mounting template (page 2 of 2)
Paragraph 2.3.5
Fig. 4.21
0 30 Minimum
Tonnage
Maximum
Tonnage
C.
Minimum
Tonnage
Maximum
Tonnage
0
Example of an ideal mount. There are no discontinuities and the tonnage builds up smoothly and fairly linearly throughout
the mount. Note that the slope starts out near zero to slightly positive for the first 10%20% and then gradually increases
until mounting is complete.
75% fit
Minimum
Tonnage
Maximum
Tonnage
0
Example of an acceptable amount whose tonnage dropped off in excess of 15 ton but not until after 75% of the fit was
achieved. The shape of this chart is indicative of too much mounting compound or a negative taper near the end of the
wheel seat and/or bore. Distribution of the radial clamping force over the length of fit is more important than the degree
of fit lost at the end of the mount. The jog in the middle of the mount is transient in nature, drop-off less than 2 ton, and
is imperceptible on most mounting charts.
2/1/04
2/1/04 G-II69
SEGMENT 4.0 RP-633
Example of an acceptable mount
Fig. 4.24
Example of a misfit where the final tonnage is not concise.
Fig. 4.25
75% fit
Minimum
Tonnage
Maximum
Tonnage
0 10 30
Example of an acceptable mount that exhibits both slip-stick and spiking. Slip-stick is a product of incompatible
surface finish between the wheel bore and axle seat. It does not cause false tonnage or alter the dependability of the
mount in any way. It is acceptable provided the wheels are centered and in gauge, the lowest concise tonnage is above
minimum allowed, and it does not occur until after the wheel is over 75% mounted.
Depending on surface finish and lubrication, it is normal for the coefficient of static friction to be as much as three times
the coefficient of sliding friction. This difference accounts for some level of acceptable spiking (historically about 30 tons).
Any misalignment multiplies this difference and compounds the amplitude of the spike. Tonnage will typically increase to
the value needed to overcome static friction and the wheel will start to slide onto the axle. Almost immediately after
motion begins tonnage will drop back to the value required to overcome sliding friction. The tonnage at the peak of the
spike should not exceed three times the drop-back tonnage or 30 tons, whichever is smaller.
Minimum
Tonnage
Maximum
Tonnage
0
Example of a misfit that appears to have achieved minimum tonnage but the final tonnage is not concise. The dark area
assumed to be slip-stick could have been drawn in. The highest tonnage that is concise is below minimum tonnage.
2/1/04
G-II70 2/1/04
SEGMENT 4.0 RP-633
Example of a misfit whose peak tonnage exceeds the minimum tonnage
Fig. 4.26
Example of a misfit where tonnage does not build up to the 75% fit line
Fig. 4.27
Example of a misfit caused by an obstruction or by excessive positive taper
Fig. 4.28
Minimum
Tonnage
Maximum
Tonnage
0
Example of a misfit whose peak tonnage exceeds the minimum tonnage but the tonnage where motion stopped was less
than the minimum tonnage. The false tonnage generated by the spike provides no additional energy to overcome in the
demount process. The area bounded by the dotted line represents the energy loss associated with the false tonnage.
75% fit
Minimum
Tonnage
Maximum
Tonnage
0
Example of a misfit that does not continue to build tonnage up to the 75% fit line. Note that there is no tonnage drop off.
This energy was lost due to lack of fit over more than 25% of the wheel seat.
Minimum
Tonnage
Maximum
Tonnage
0
This is the false
energy generated
by the obstruction
This area represents the energy
difference between this mount and
an ideal mount of the same tonnage.
Example of a misfit caused by an obstruction or by excessive positive taper in the second half of the wheel seat and/or
bore. Were it not for the obstruction or taper problem, the chart would not have made minimum tonnage.
2/1/04
2/1/04 G-II71
SEGMENT 4.0 RP-633
Example of a misfit indicating an alignment problem
Fig. 4.29
Axle centering gauge
(for working drawings of gauges, see paragraph 5.0)
Rule 1.4.5 and Paragraphs 2.3.8 and 2.3.10
Fig. 4.30
Gauge for locating first wheel
(For Working Drawings of Gauges, See Rule 5.0)
Fig. 4.31
Minimum
Tonnage
Maximum
Tonnage
0 10
30
Example of a misfit that indicates an alignment problem. The spike exceeded 30 ton, and the peak tonnage was more
than twice the fall-back tonnage indicating that the coefficient of static friction was more than three times the coefficient
of sliding friction. An undetermined amount of the energy applied was needed to overcome the misalignment and cannot
be attributed to fit.
C
L
AXLE
Scribe mark at center from each end of axle, adjusting scribe until exact center is found.
C
L
Mount first wheel until gauge contacts scribe mark at center of axle. Second wheel may be mounted with this gauge, but
wheels must be checked with back-to-back mounting gauge.
2/1/04
G-II72 2/1/04
SEGMENT 4.0 RP-633
Gauge for mounting second wheel
(for working drawings of gauges, see paragraph 5.0)
Fig. 4.32
Gauge limits for mounting wheels for freight cars and passenger equipment cars
Rules 1.4.5, 1.5.3, and 1.7.9 and Paragraphs 2.8.2 and 2.8.17.1
Fig. 4.33
Method of permanently stamping front face of wheel hub at wheel mounting shop
Rules 1.4.11 and 1.7.10
Fig. 4.34
1 "
1 "
MOUNTING DIMENSIONS
WHEELS ARE OUT OF GAGE IF THIS DIMENSION
IS LESS THAN 53 IN. 53
3
32"
IN.
EXCEEDS 53
3
8 "
IN. 53
3
8 "
IN.
FOR ALL FREIGHT CAR
WHEELS AND WIDE FLANGE
PASSENGER CAR WHEELS
FOR OTHER THAN
FREIGHT CAR WHEELS
SHOP CODE
YEAR
COMPANY
MONTH
B
6
G
W
7
2
Note: Mounting stamping should be of sufficient depth that it will not disappear easily due to wear and/or corrosion.
2/1/04
2/1/04 G-II73
SEGMENT 4.0 RP-633
Mounted wheel set run-out to be measured with bearing mounted and
wheel set supported on bearings as pictured below.
Radial
Plane
Mounted wheel run-out check
Rules 1.4.12 and 1.5.4
Fig. 4.35
2/1/04
G-II74 2/1/04
SEGMENT 4.0 RP-633
AAR-1B wide flange contour for freight car wheels
Rules 1.5.2 and 1.5.3
Fig. 4.36
GAUGE POINT
BASELINE
1
2
3
4
5
6
7
8
9
1.8232
TAPER 1:20
(1:17 1:23)
0.3754
BASELINE
R 1.5000
+ 0.0625
0.0625
GAUGE
POINT
R 0.5625
+ 0.0625
0.0625
R 0.6250
+ 0.0313
0.0938
1.3750
3.0625
75
0.0370
R 0.6875
R 0.3750
+ 0.0625
0.0000
1.0000
R 2.6250
5.0938
T
A
P
E

L
I
N
E
R 0.6250
R 0.6250
GAUGE POINT
D
C
B
E
F
R 0.6875
R 0.3750
R 0.5625
R 2.6250
A
R 1.5000
5.7188
+ 0.1250
0.1250
Centers of Radii Relative to
Gauge Point
Point X Y
A 1.1969 1.1499
B 0.5890 0.2496
C 0.5890 0.3121
D 0.3622 0.0971
E 0.5803 0.0075
F 1.0603 0.8128
Intersection Points
Relative to Gauge Point
Point X Y
1 1.3750 0.6246
2 1.1471 0.0318
3 0.5890 0.3754
4 0.0901 0.1610
5 0.0000 0.0000
6 0.0370 0.1381
7 0.2923 0.4757
8 0.6314 0.6246
9 0.9854 0.6853
2/1/04
2/1/04 G-II75
SEGMENT 4.0 RP-633
AAR1B narrow flange contour for freight car wheels
Rules 1.5.2 and 1.5.3
Fig. 4.37
GAUGE POINT
D
C
B
E
F
R 0.6875
R 0.3750
R 0.5625
R 1.3750
A
GAUGE POINT
BASELINE
1
2
3
4
5
6
7
8
9
1.8030
TAPER 1:20
(1:17 1:23)
0.3750
BASELINE
R 1.5000
+ 0.0625
0.0625
GAUGE
POINT
R 0.5625
+ 0.0625
0.0625
3.0625
75
0.0084
R 0.6875 R 0.3750
+ 0.0625
0.0000
1.0000
5.0938
T
A
P
E

L
I
N
E
R 0.6250
5.7188
+ 0.1250
0.1250
1.1563
+ 0.0625
0.0000
R 0.3750
0.0370
R 1.3750
R 1.5000
R 0.3750
Centers of Radii Relative to
Gauge Point
Point X Y
A 0.2044 0.6418
B 0.5625 0.3125
C 0.5625 0.0000
D 0.3706 0.0659
E 0.5720 0.0387
F 1.0520 0.8440
Intersection Points
Point X Y
1 1.1563 0.4434
2 0.8501 0.2407
3 0.5625 0.3750
4 0.1403 0.2301
5 0.0084 0.0312
6 0.0286 0.1069
7 0.2840 0.4445
8 0.7485 0.6250
9 0.9771 0.6542
2/1/04
G-II76 2/1/04
SEGMENT 4.0 RP-633
AAR1B narrow flange contour for freight car wheels
Rules 1.5.2 and 1.5.3
Fig. 4.37 (Concluded)
NOTE: TAPER 1" IN 40" FOR AMTRAK WHEELS
GAGING POINT
TAPER 1" IN 20"
BASE LINE
T
A
P
I
N
G

L
I
N
E
VERTICAL
REFERENCE
LINE
3
64"
5 "
1
8 "
5
8 "
5
8 "
R
1
16"
31
32"
1
11
16"
+
1
16"
0"
1
5
32"
1 "
5
8 "
+
1
16"
0"
1"
11
16"
R

1
16"
2
31
32"
R
29
32"
R
1
7
8 "
R
5
8 "
R
5
8 "
R
Narrow flange tapered tread contourlocomotive and Amtrak (formerly Standard S-621-79)
Narrow flange cylindrical tread contour (formerly Alternate Standard S-622-78)
GAGING
POINT
TAPER 1" IN 20"
T
A
P
I
N
G

L
I
N
E
VERTICAL
REFERENCE
LINE
NOTE: TAPER 1" IN 40" FOR AMTRAK WHEELS
3
64"
5 "
1
8 "
5
8 "
5
8 "
R
1
16"
+
1
16"
0"
1
5
32"
1 "
5
8 "
+
1
16"
0"
1"
11
16"
R

1
16"
2
31
32"
R
29
32"
R
1
7
8 "
R
5
8 "
R
5
8 "
R
2"
1
11
16"
31
32"
CYLINDRICAL TREAD
2/1/04
2/1/04 G-II77
SEGMENT 4.0 RP-633
Acceptance gauge for AAR 1B narrow and wide flange steel wheels
Rules 1.5.2 and 1.5.3
Fig. 4.38
INTERSECTION POINTS
1 (0.0841873, -1.49764)
2 (0.4289, -1.4374)
3 (0.769141, -1.2878)
4 (1.02338, -0.950724)
5 (1.0603, -0.8128)
CENTERS OF RADII
A (0.000, 0.000)
B 0.480, -0.8053)
R.5625
4.000
1.094
1.987
2.8624
R1.500
A
B
1
2
3
4
5
BASELINE
WHEEL CONTOUR ACCEPTANCE GAUGE
FOR AAR 1B NARROW & WIDE FLANGE
6.500
1.469
3
8 "
3
8 "
.750
VERIFY WITH CONTOUR MAPPING
MAX MANUFACTURE DEVIATION: .003"
MAX RECERTIFICATION DEVIATION: .005"
MATERIAL:
STAINLESS STEEL 17-7
1
8 "
THICKNESS
HARDENED
2/1/04
G-II78 2/1/04
SEGMENT 4.0 RP-633
Verifying renewed 1B wide flange contour using AAR 1B acceptance gauge
Rule 1.5.2
Fig. 4.39
VERIFY TAPER ANGLE
VERIFY WORKING CONTOUR
NOTE: 1/32-IN. PIN MUST NOT PASS UNDER GAUGE AT ANY POINT.
2/1/04
2/1/04 G-II79
SEGMENT 4.0 RP-633
Verifying renewed 1B narrow flange contour using AAR 1B acceptance gauge
Rule 1.5.2
Fig. 4.40
VERIFY WORKING CONTOUR
VERIFY TAPER ANGLE
NOTE: 1/32-IN. PIN MUST NOT PASS UNDER GAUGE AT ANY POINT.
2/1/04
G-II80 2/1/04
SEGMENT 4.0 RP-633
AAR-1B wide flange contour for freight car wheels
Rules 1.5.2 and 1.5.3
Fig. 4.41
B
C
D
A
1
2
3
4
5
6
7
8
9
2
5.0938
5.7188
R R
R
5
8 "
F
1.8232
BASELINE
R2.6250
2.8624
R.3750
R1.5000
R.5875
R.6250
1.000
R.5625
R
E
MAX MANUFACTURE DEVIATION: .003 IN.
MAX RECERTIFICATION DEVIATION: .005 IN.
MATERIAL: STAINLESS STEEL 17-7
THICKNESS: 1/8
HARDENED
SCALE: 1X
Intersection Points
Point X Y
1 1.3750 0.6246
2 1.1471 0.0318
3 0.5890 0.3754
4 0.0901 0.1610
5 0.0000 0.0000
6 0.0370 0.1381
7 0.2923 0.4757
8 0.6314 0.6246
9 0.9854 0.6853
Centers of Radii
Point X Y
A 1.1969 1.1499
B 0.5890 0.2496
C 0.5890 0.3121
D 0.3622 0.0971
E 0.5803 0.0075
F 1.0603 0.8128
2/1/04
2/1/04 G-II81
SEGMENT 4.0 RP-633
AAR-1B narrow flange contour for freight car wheels
Rules 1.5.2 and 1.5.3
Fig. 4.42
B
C
D
A
1
2
3
4
5
6
7
8
9
2
5.7188
R
R
R
5
8 "
F
BASELINE
R1.3750
2.8624
R.3751
R1.5000
R.5875
R.3750
1.000
R
R.5625
E
2
11
32"
TAPER 1:20
(1:17 1:23)
MAX MANUFACTURE DEVIATION: .003 IN.
MAX RECERTIFICATION DEVIATION: .005 IN.
MATERIAL: STAINLESS STEEL 17-7
THICKNESS: 1/8
HARDENED
SCALE: 1X
Intersection Points
Point X Y
1 1.1563 0.4440
2 0.8531 0.2370
3 0.5625 0.3750
4 0.1319 0.2234
5 0.0068 0.0255
6 0.0269 0.1067
7 0.2804 0.4423
8 0.7487 0.6250
9 0.9771 0.6541
Centers of Radii
Point X Y
A 0.2044 0.6418
B 0.5625 0.3125
C 0.5625 0.0000
D 0.3706 0.0659
E 0.5720 0.0387
F 1.0520 0.8440
2/1/04
G-II82 2/1/04
SEGMENT 4.0 RP-633
Method of applying steel wheel gauge on worn flange wheel
Rule 1.5.2
Fig. 4.43
NOMINAL AAR 1B
CONTOUR
BASELINE
2.876
.357
CONDEMNING LINE
(FREIGHT CAR SERVICE)
MEASURING POINT
The pointer indicates amount of metal in sixteenths of an inch to be turned off tread to restore full
flange contour with a witness groove. The side scale shows amount of metal on tread above
measuring line before turning. In this illustration, 7/16 in. must be turned off tread to restore full flange
contour. The amount of service metal available after turning is 6/16 in. A finger marked NF or a
finger having no identifying marking is used for gaging the flanges of steel wheels used on freight
cars, passenger cars and locomotives. The WF finger may be used when restoring wide flange
contour to wheels.
2/1/04
2/1/04 G-II83
SEGMENT 4.0 RP-633
Method of Applying Steel Wheel Gauge on Worn Flange Wheel
Rule 1.5.2
Fig. 4.44
0
6
5
4
3
2
1
0
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
1
1
2
2
2
1
2
3
9
0
8
6
4
2
3
8 "
2
7
8 "
BASELINE
0
6
5
4
3
2
1
0
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
1
1
2
2
2
1
2
3
9
0
8
6
4
2
"
CONDEMING LINE
MEASURING POINT
3
8 "
7
16"
The pointer indicates amount of metal in sixteenths of an inch to be turned off tread to restore full
flange contour with a witness groove. The side scale shows amount of metal on tread above
measuring line before turning. In this illustration, 7/16 in. must be turned off tread to restore full flange
contour. The amount of service metal available after turning is 6/16 in. A finger marked NF or a
finger having no identifying marking is used for gaging the flanges of steel wheels used on freight
cars, passenger cars and locomotives. The WF finger may be used when restoring wide flange
contour to wheels.
2/1/04
G-II84 2/1/04
SEGMENT 4.0 RP-633
Method of applying AAR steel wheel gauge to measure amount of metal to be turned off tread to remove flat spot and
also extra metal to be turned off to restore flange contour
AAR steel wheel gauge
Rule 1.5.2
Fig. 4.45
CONDEMNING LINE
MEASURING POINT
"A"
GAUGE APPLIED
TO OUTSIDE OF
FLAT SPOT
"B"
GAUGE APPLIED
IN FLAT SPOT
CONDEMNING LINE
MEASURING POINT
2/1/04
2/1/04 G-II85
SEGMENT 4.0 RP-633
Method of applying AAR steel wheel gauge to measure amount of metal to be turned off tread to remove flat spot and
also extra metal to be turned off to restore flange contour
Rule 1.5.2
Fig. 4.46
0
6
5
4
3
2
1
0
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
1
1
2
2
2
1
2
3
9
0
8
6
4
2
"
CONDEMING LINE
MEASURING POINT
3
8 "
7
16"
SKETCH A
GAUGE APPLIED OUTSIDE OF FLAT SPOT
"
CONDEMING LINE
MEASURING POINT
3
8 "
SKETCH B
GAUGE APPLIED IN FLAT SPOT
0
6
5
4
3
2
1
0
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
1
1
2
2
2
1
2
3
9
0
8
6
4
2
5
16"
2/1/04
G-II86 2/1/04
SEGMENT 4.0 RP-633
Method of applying AAR steel wheel gauge to check depth of witness groove in flange
Fig. 4.47
Method of applying AAR steel wheel gauge to check location of witness groove in flange
Fig. 4.48
NOT MORE
THAN
3
64"
DEEP
NOT LESS
THAN
3
8 "
2/1/04
2/1/04 G-II87
SEGMENT 4.0 RP-633
Method of applying AAR steel wheel gauge to check depth of witness groove in flange
Fig. 4.49
Method of applying AAR steel wheel gauge to check location of witness groove in flange
Fig. 4.50
0
6
5 4 3 2 1 0
3

F
R
T
4
S
C
R
A
P
P
A
S
S
1

---
S
C
R
A
P
1
1
2
2
2
1
2
3
9
0
8
6
4
2
NOT MORE THAN
3
64"
DEEP
0
6
5
4
3
2
1
0
3 F R T
4 S C R A P
P A S S
1 - - -
S C R A P
1
1
2
2
2
1
2
3
9
0
8
6
4
2
NOT LESS
THAN
3
8 "
BASELINE
2/1/04
G-II88 2/1/04
SEGMENT 4.0 RP-633
Method of gaging vertical flangescondemnable
Rule 1.5.2 and Paragraphs 2.8.2, 2.8.11, and 2.8.12
Fig. 4.51
2/1/04
2/1/04 G-II89
SEGMENT 4.0 RP-633
Condemning limit for flange height using AAR steel wheel gauge when apex of flange contacts underside of horizon-
tal member, wheel is condemnable
Rule 1.5.2 and Paragraphs 2.8.2, 2.8.11, and 2.8.12
Fig. 4.52
1"
2/1/04
G-II90 2/1/04
SEGMENT 4.0 RP-633
Shattered rimWhy Made Code 71
Paragraph 2.8.1
Fig. 4.53
2/1/04
2/1/04 G-II91
SEGMENT 4.0 RP-633
Paragraphs 2.8.1, 2.8.7.5, and 2.8.7.1
Fig. 4.54
Heat checks (Not normally condemnable)
Thermal cracksWhy Made Code 74
2/1/04
G-II92 2/1/04
SEGMENT 4.0 RP-633
Paragraphs 2.8.1, 2.8.2, 2.8.7.1, and 2.8.7.3
Fig. 4.55
2/1/04
2/1/04 G-II93
SEGMENT 4.0 RP-633
Paragraphs 2.8.1, 2.8.2, 2.8.4, and 2.8.5
Fig. 4.56
Spread rimWhy Made Code 72
Subsurface defect, found on turning wheelWhy Made Code 88
2/1/04
G-II94 2/1/04
SEGMENT 4.0 RP-633
Paragraphs 2.8.1, 2.8.2, 2.8.6.1, and 2.8.8
Fig. 4.57
Shelled treadWhy Made Code 75
Built-up treadWhy Made Code 76
Slid flatWhy Made Code 78
Built-up treadWhy Made Code 76
2/1/04
2/1/04 G-II95
SEGMENT 4.0 RP-633
Grooved tread wheelWhy Made Code 77
Paragraphs 2.8.1, 2.8.2, and 2.8.18
Fig. 4.58
Cracked or broken plateWhy Made Code 88
Paragraphs 2.8.1, 2.8.2, and 2.8.15
Fig. 4.59
2/1/04
G-II96 2/1/04
SEGMENT 4.0 RP-633
Scrape, dent, or gouge in wheel surfacesWhy Made Code 80
Paragraphs 2.8.1, 2.8.2, and 2.8.19
Fig. 4.60
2/1/04
2/1/04 G-II97
SEGMENT 4.0 RP-633
Application of portable hydraulic bearing puller (Recommended)
Rule 1.8.1.2
Fig. 4.61
ADAPTER SHOE
REACH RODS
PRESS RAM
PILOT SLEEVE SOLID
PULLING RING
PULLING RING ADAPTER
DUST GUARD RING
BEARING ASSEMBLY
ADAPTER SHOE AND REACH RODS
TO SUIT PRESS CONDITIONS
FIXTURE FOR PULLING A BEARING IN A BEARING PRESS OR WHEEL PRESS
2/1/04
G-II98 2/1/04
SEGMENT 4.0 RP-633
Tools for applying bearing to axle (recommended)
Rules 1.8.2.4 and 1.8.2.8
Fig. 4.62
1
8 "
45 CHAMFER
BOTH ENDS
DRILL ONE
HOLE F DIA.
DRIVE FIT
3"
A
B
G
C
S
J
D
L H
K
M
N
P
A
PILOT SLEEVE
HEX HEAD BOLT
MOUNTING SLEEVE
SECTION AA
DRILL E DIA.
D
I
A
.

+

.
0
0
2
"

.
0
0
0
"
D
I
A
.

.
0
0
2
"
D
I
A
.
30
D
I
A
.
B
O
L
T
C
I
R
C
L
E
D
I
A
.
D
I
A
.
PIN THREAD
R DIA. UNC-2A
1"
1
"
D
I
A
.
3"
HEAT TREAT CAP
TO 190242 BRINELL
1
"
1
16"
3
16"
A
1
64"
"
1 "
" R
"
1 "
1 "
1
8 "
45 CHAMFER
BOTH ENDS
1 "
"
12" R
D
I
A
.

.
0
0
2
"
" R
"
Journal Pilot Sleeve Mounting Sleeve Pin Hex Head Bolt
Class Size A B C D E F G H J K L M N P R S
For Freight Cars
D 5 1/2 10 8 1/2 5.165 4.687 3 1/2 29/32 47/64 15/16 11 3/8 5 3/4 5.198 3/4 47/64 7/8 8 1/2 7/89 1 1/4
E 6 11 9 3/8 5.665 5.187 3 7/8 1 1/32 27/32 1 7/16 12 9/16 6 1/4 5.698 3/4 27/32 15/16 9 3/8 18 1 3/8
F 6 1/2 12 10 1/4 6.165 5.687 4 1/4 1 5/32 61/64 1 9/16 13 1/4 6 3/4 6.198 1 61/64 1 10 1/4 1 1/87 1 1/2
G 7 12 10 1/4 6.978 6.500 4 5/8 1 9/32 1 5/64 11 1/16 13 7 9/16 7.012 1 1/4 1 5/64 1 1/8 10 1/4 1 1/47
1 5/8
K 6 1/2 9 Use Class F mounting pilot (with 1 1/2-in. spacer) 10 3/4 1 1/87
For Amtrak Cars
EE 6 dia 8 3/4 5.978 5.500 4 1/4
3 1/2
1 5/32 61/64 1 9/16 9 1/2 6 13/16 6.010 1 63/64 1 8 3/4 1 1/87 1 1/2
EE 5 1/2 dia 8 3/4 5.478 5.000 3 29/32 47/64 1 5/16 9 1/2 6 9/16 5.512 1 47/64 7/8 8 3/4 7/89 1 1/4
G 6 1/2 dia 9 3/4 6.478 6.000 3 7/8
5
29/32 47/64 1 5/16 10 3/4 7 9/16 6.512 1 47/64 7/8 9 3/4 7/89 1 1/4
2/1/04
2/1/04 G-II99
SEGMENT 4.0 RP-633
Applying bearing to axle (recommended method)
Rules 1.8.2.4 and 1.8.2.8
Fig. 4.63
Spring loaded pilot and assembly sleeve for application to press ram for mounting bearings
Spring loaded pilot applying bearing with roller bearing press
2/1/04
G-II100 2/1/04
SEGMENT 4.0 RP-633
Seating pressures to be posted in work area in roller bearing mounting shops
Rule 1.8.2.8
Fig. 4.64
Comparison of Amtrak axle end cap assemblies
Rule 1.8.3.1
Fig. 4.65
Note: Amtrak inboard bearing seating pressure is 50 5 ton maximum for all sizes. Seating pressures shown are the final
pressure gauge reading that is required to properly seat the bearing backing ring against the axle fillet radius.
Class
Journal Size
(in.)
Seating Pressures
(ton)
For Freight Cars
D 5 1/2 10 50 5
E 6 11
F 6 1/2 12
K 6 1/2 9
G 7 12 65 5
For Amtrak Cars
G 6 1/2 Diameter 65 5
EE All diameters 55 5
CAP SCREW
CA-PLUG
CLASS EE
REDUCING
BUSHING
LOCKING PLATE
LUBRICANT
FITTING
NEOPRENE
GASKET
CLASS G
CAP SCREW
LOCKING PLATE
LUBRICANT
FITTING
2/1/04
2/1/04 G-II101
SEGMENT 4.0 RP-633
Cap screw torque values
Rules 1.8.3.1 and 1.8.3.2 and Paragraph 2.1.2.3
Fig. 4.66
Bending locking plate tabs with rib-joint pliers
(Recommended)
Tabs bent against adjacent flats
Tabs bent against alternate flats Preferred bending when one tab is centered on corner
Note: After proper torque is attained, cap screws must never be repositioned for alignment of tabs to flats.
Proper method for securing locking plate
Rule 1.8.4.3
Fig. 4.67
Class Journal Size (in).
Cap Screw
Size Torque (ftlb)
a/
a/
Torque wrenches must be accurate within 4 %.
Cap screw torque is in ftlb. It is to be posted in the work area in roller bearing mounting shops.
For Freight Cars
D 5 1/2 10 7/89 160
E 6 11 18 290
F 6 1/2 12 1 1/87 420
G 7 12 1 1/47 490
K 6 1/2 9 1 1/87 420
L 6 8 18 290
M 7 9 1 1/87 420
For Amtrak Cars
G
6 1/2 diameter 7/89
(High Strength)
315
7/89 145
EE 6 diameter 7/89 145
EE 5 1/2 diameter 3/410 115
2/1/04
G-II102 2/1/04
SEGMENT 4.0 RP-633
Checking mounted lateral (recommended method)
Rule 1.8.4.1
Fig. 4.68
Using a magnetic base dial indicator, place the base on its outer ring with the dial indicator anvil
resting on the bearing cap screw or the wheel hub.
2/1/04
2/1/04 G-II103
SEGMENT 4.0 RP-633
Manufacturers allowable tolerance for mounted lateral
(to be posted at work area in mounting shops)
Rule 1.8.4.1
Fig. 4.69
Notes:
1. Mounted lateral is 0.006 .020 for Amtrak F (6 1/2 12) inboard, G (6 1/2-in. diameter), EE (6-in. diameter) and
EE (5 1/2-in. diameter) bearing applications.
2. If a tapered bearing rotates freely by hand but indicates less than .001-in. lateral on the dial indicator, the application is
satisfacory for service.
Manufacturer Bearing Certification No. Mounted Bearing Lateral
Timken 1, 1A
.001 in..015 in.
Brenco 5, 5A
General Bearing 6, 6A, 6B, 21
Bower 8
NTN 10
NSK 11,11A
Nachi 12
FAG 13
Koyo 14, 24
Magnus 16
NTN 19 (10A)
Timken 20
NSK 22
SKF Tapered 23
Brenco 25
FAG 26
Timken 27
Brenco 28
SKF/RBI 29
SKF 30
2/1/04
G-II104 2/1/04
SEGMENT 4.0 RP-633
Shop status codes
Rules 1.7.10 and 1.8.5.2
Fig. 4.70
Status Code Explanation
1 Wheel mounting shopfreight car (complete with wheel press & boring mill)
2B Approved roller bearing repair shopfreight and Amtrak passenger car
2E Roller bearing cone bore and outer ring counterbore plating approval
2F Approved roller bearing repair shopfreight car
2G Cone face grinding
2P Approved roller bearing repair shopAmtrak passenger car
2S Roller bearing cone stress relieving approval
3A M-967 Axle repair shopjournal, seal wear ring groove and water etch repairsfreight car
3B M-967 Axle repair shopjournal repairs onlyfreight car
3C M-967 Axle repair shop-dust guard repairs onlyfreight car
4 Wheel and axle shop-locomotive
5 Wheel and axle lathe(s)freight car
6 Wheel lathe(s)freight car
6A Wheel lathe(s)Amtrak passenger car
7 Axle lathe(s)freight car
7A Axle lathe(s)Amtrak passenger car
8 Wheel and axle shoppassenger car
8A Wheel and axle shopAmtrak passenger car
9 Roller bearing mountingfreight and Amtrak passenger car
9A Removal and reapplication of roller bearing end caps
Note: For a railroad or company having only one shop, it is not necessary to use shop code letters; however, Railroad or
Company Marks, as shown above, must be used.
The above is provided as information. For current facility approval status, refer to the latest Circular LetterListing of Repair
Facilities, Status Codes, and Shop Identification Marks.
2/1/04
2/1/04 G-II105
SEGMENT 4.0 RP-633
Wheel shopperiodic machinery inspection
Rules 1.1.1, 1.1.7, 1.2.2, 1.4.1, 1.5.1, 1.7.1, and 1.7.2
Fig. 4.71
WHEEL SHOPPERIODIC MACHINERY INSPECTIONPAGE 1 OF 2 101A
(SEE RULE 1.7.1)
Boring MillUse Test WheelParagraph 2.2.2
Machine
Number
Dial Gauge (Full) Reading Bore Condition of Machine
and Corrective Action Radial Error Plane Error OR TA
Before*
After**
Before*
After**
Before*
After**
Before*
After**
Axle LatheUse MicrometersCheck WorkRules 1.1.1 and 1.1.7
Machine
Number
Seat Seat
Centers
Condition of Machine
and Corrective Action OR TA OR TA
Before*
After**
Before*
After**
Before*
After**
Before*
After**
Before*
After**
Before*
After**
Before*
After**
Mounted Axle LatheUse MicrometersCheck WorkRule 1.2.2
Machine
Number
Centers
and Corrective Action
Before*
After**
Before*
After**
Wheel LatheUse Dial GaugeCheck WorkRule 1.5.1
Machine
Number
Eccentricity
Centers
and Corrective Action Left Side Right Side
Before*
After**
Before*
After**
Wheel PressRule 1.4.1
Machine
Number
Date Condition of Machine
and Corrective Action Recorder Gauges
* Before any adjustment OROut of Round
** After adjustment TATaper
Location: _______________________________________
Distribution: Original to ___________________________
1 copy to Shop File
Signature:_________________________________________________
Title: _____________________________________________________
Date:_____________________________________________________
2/1/04
G-II106 2/1/04
SEGMENT 4.0 RP-633
Wheel shopperiodic machinery inspection
Rules 1.1.8 and 1.8.1.2
WHEEL SHOPPERIODIC MACHINERY INSPECTIONPAGE 2 OF 2 101B
(SEE RULE 1.7.1)
Mandatory Inspection of Magnetic Particle Testing EquipmentRule 1.7.2
Machine
Number
1. Date of preparation of bath solution, bath container cleaned, agitation, and circulation system flushed
and filtering screens cleaned ________________________________________________________
2. The amount of suspensoid ____________________ and powder ____________________ used in
preparation of bath solution.
3. Concentration and contamination of bath solution, amount of magnetic powder __________ mL, and
amount of contamination-dirt, chips, or other foreign matter and magnetic powder __________ mL.
4. Test for ultraviolet light, light meter having a 75-footcandle scale with 10 multiplying disc or equivalent,
reading __________ footcandle or direct reading meter __________ mW/cm
2
.
Inspector: ______________________________________ Operator:_______________________________________
Torque Wrenches
S/N_____________ Set at ________________ ftlb Tested__________________ Date By _________________
S/N_____________ Set at ________________ ftlb Tested__________________ Date By _________________
Gauge for Centering Wheels on Axles
Length of gauge 26 35/64 in. Checked at ______________________________ by ____________________________
(Length of gauge 26 5/8 in. for Amtrak passenger cars)
Back-to-Back Mounting Gauge for Freight Car Wheels
Gauge set for 53 in. 53 3/32 in. and 53 3/8 in. Show any adjustments
________________________ Checked by ___________________________________________________________
Location: _______________________________________
Distribution: Original to ___________________________
1 copy to Shop File
Signature: _________________________________________________
Title: _____________________________________________________
Date: _____________________________________________________
2/1/04
2/1/04 G-II107
SEGMENT 4.0 RP-633
AAR failed axle report
Paragraph 3.1.1
Fig. 4.72
2/1/04
G-II108 2/1/04
SEGMENT 4.0 RP-633
Paragraph 3.1.1
Fig. 4.72 (Continued)
AAR standard axle marking
Note 1. Laboratory acceptance stampfor use by purchaser to marked prior to shipment by producer
Note 2. Serial number when specified (required after 1980)
Note 3. Mfg. Name or Brand:
BS
a/
a/
No longer in production
Bethlehem Steel Corporation, Johnston
Plant
SFC or
SF
a/
Standard Forgings
BF Bumar Fablok S.A. (Poland) SSD Standard Steel Division.
CB
a/
Cobrasma (Brazil) SMI Sumitomo Metal Industries Ltd. (Japan)
CF Valdunes, Dunkerque plant (France)
Previously Creusot-Loire)
SPT
a/
British Steel, Templeborough & Ickles Works
(England)
DDAP Dneproderzhinsk axle (Ukraine) SW SWASAP (South Africa)Dorbyl
DSS JSC DneproSpetsStal (Ukraine) T
a/
British Steel, Trafford Park Works (England)
HM Huta 1 Mosa (Poland) THM Taiyuan Heavy Machinery (PRC)
JAW Standard Forged Products, Johnstown TW plus
a/
Letter T and a number in a diamond. Hawker
Siddeley Canada Inc., Trenton Works
KW
a/
Klockner (W. Germany) UF Ural Forge (Russia)
L Lovere (Italy)
(previously Italsider)
(previously Terni)
USS-F
a/
United States Steel Corporation Fairfield
Works
LCKZ LugCentroKuZ (Ukraine) USS-G
a/
United States Steel Corporation Gary Works
LP Lucchini Poland (Poland) USS-H
a/
United States Steel Corporation, Homestead
Works
MK
a/
Makrotek (Mexico) V Valdunes, Valenciennces plant (France)
Previously Creusot-Loire)
MRF Standard Forged ProductsMcKees
Rocks Forgings
WAP Ministry of Railways (India)
MW
a/
Mafersa (Brazil) ZB Zebezarny A Dratovny (Czech Republic)
SCOT Scot Forge
NOTE 7
NOTE 6
NOTE 3
NOTE 5
NOTE 2
NOTE 1
NOTE 4
11 66
USS H
6
6

A
0
0
1 0
0
0
0
0
T
F
L
NOTE 11
NOTE 12
NOTE 13
NOTE 9
NOTE 8
V1BW
5-89 Y-AT
X-BN-H
8-85
ROLLER BEARING
FREIGHT CARS
ONLY
NOTE 7 NOTE 6
NOTE 3
NOTE 5
NOTE 2
NOTE 1
NOTE 4
11 66 66 A001 F
L T 00000 USS H
11 66
USS H
NOTE 8
NOTE 9
ROLLER BEARING
PASSENGER CARS
ONLY
CIRCUMFERENTIAL DEVELOPMENT
OF AXLE END
2/1/04
2/1/04 G-II109
SEGMENT 4.0 RP-633
Paragraph 3.1.1
Note 4. Month and year made
Note 5. Letter T stamped adjacent to the heat number or the serial number. Axle has been ultrasonically inspected by
the manufacturer (stamping not required after 1980).
Note 6. Grade of axle:
U Untreated
G Quenched and tempered
F Double normalized and tempered
H Normalized, quenched, and tempered
Note 7. Heat number
Note: Stamping mounting information on axles in these locations
was discontinued October 1, 1972. See Rule 1.4.11.
Note 8. Conversion date
Note 9. X (wheel shop symbol)
Note 10. Converted axles must be stamped with the conversion date (Note 8. location) and the letter X followed by the
wheel shop symbol (Note 9. location). Manufacturers pertinent information must be reapplied to the end of axle,
if available (Note 1. through Note 7.)
Note 11. Axles repaired by Specification M-967 processes must be stamped with the letter V followed by one or two
sequential numbers identifying the journals repaired and by the AAR-assigned identifying marks (Note 11
location). Sequential odd numbers will be used to identify journal repairs and the end of axle on which markings
are applied; sequential even numbers will be used for the other end. For example, V1BW, V23BRX means
journal at marking end of axle repaired and followed later by both journals being repaired with journal at marking
end being repaired a second time.
Note 12. Shops finish machining new axles, excluding wheel seats, will show the letter Y followed by wheel shop symbol
(Note 12 location). Axle manufacturers finish machining axles will use brand shown in Note 3 above.
Shops that finish-machine new axles, excluding wheel seats, will show the letter Y followed by the wheel shop
symbol (Note 12 location). Axle manufacturers that finish-machine axles will use the brand shown in Note 3 above.
2/1/04
G-II110 2/1/04
SEGMENT 4.0 RP-633
Defective wheels removed, causing derailments or line-of-road setouts
Paragraphs 3.1.2, 3.3.4, and 3.3.6
Fig. 4.73
DEFECTIVE WHEELS REMOVED, CAUSING DERAILMENTS, OR LINE-OF-ROAD SETOUTS
Instructions: This report is to cover wheels which are removed for defects, represented by the following WHY MADE CODES 66, 68,
71, and 83 (see Field Manual of AAR Interchange Rules, Rule 41). All items should be completed. If the numbers or letters are illegible,
draw a horizontal line in the box or boxes affected.
2/1/04
2/1/04 G-II111
SEGMENT 4.0 RP-633
Defective wheels removed, causing derailments or line-of-road setouts
Paragraphs 3.1.2, 3.3.4, and 3.3.6
Explanation of wheel manufacturers markings (Blocks 3536)
A
a/
a/
Note: No longer in production.
Armco GI Griffin, Kansas City Plant
B
a/
Bethlehem (BW) GT Griffin, Winnipeg Plant
C
a/
U.S. Steel CorpPittsburgh Plant (Carnegie) (CW) GB
a/
Griffin, Bensenville Plant
E Edgewater (EW) GS Griffin, Bessemer Plant
F ValdunesDunkerque Plant (France) (FW)
(previously Creusot-Loire)
GK Griffin, Keolcuk Plant
G
a/
U.S. Steel CorpGary Plant FM
a/
Fundiciones De Hierro V Acero (Mexico)
J Sumitomo (Japan) (JW) SJ
a/
Abex, Johnstown Plant
KW Klockner (W. Germany) SO
a/
Abex, Calera Plant (ABC Rail after July 1987)
L Lovere (Italy) (LW) (previously Italsider) (previously Terni) C ABC Rail, Calera Plant (previously Abex) The letters C, S, or T directly precede the
wheel serial number for wheels
manufactured prior to or about April
1978.
MW
a/
Mafersa(Brazil) S
a/
Abex, St. Louis Plant
P British SteelTempleborough and Ickles Work (England) T
a/
Abex, Toledo Plant
S Standard Steel Division (SW) CZ Iochpe-Maxion, Brazil
T
a/
British SteelTrafford Park Works (England) (TW) PT ABB British Wheelsets
V ValdunesValenciennes Plant (France) (VW)
(previously Usinor) (see F above.)
CF Construcciones y Auxiliar de Ferrocarriles (Spain)
Z
a/
Canadian Steel Wheel Division (ZW) RW SMA Rolling Stock Assemblies (Romania)
GC
a/
Griffin, Chicago Plant SC SCAW Metals Ltd (South Africa)
GC Griffin, Columbus Plant WI Ministry of Railways (India)
GL Griffin, Colton Plant ZD Zelezaroy Aliatovuy (Czech Republic)
GY
a/
Griffin, St. Hyacinthe Plant
Explanation of Class of Heat Treatment
(Blocks 2930)
Explanation of Brake Shoe Codes
(Blocks 5758)
A AE CComposition shoe, high friction
BRim treated BEEntire wheel treated PHigh phosphorus cast iron shoe
C CENot used after 1980) SStandard cast iron shoe
L LE UType of brake shoe unknown
UUntreated UIUntreated (cast after 12/31/63 and before 1/1/70 by Southern (ABEX) only)
Instructions for Completing AAR Wheel Failure Form MD-115
Box 2324 Enter steel wheel gauge narrow flange finger readings, 00 through 09, using 10 if reading greater than 09.
Box 2728 Be careful to select proper Why Made code. See paragraphs 2.8.1 through 2.8.20.3 or the Field Manual of the AAR Interchange Rules,
Rule 41, Section A, for applicable descriptions.
Box 2930 Put first letter in box 29.
Box 3134 Put first letter in box 31 and first number in box 33.
Box 3536 Wheel manufacturer. Put first letter in box 35. Note that Griffin wheels have risers on front of plate and that (ABEX)* Southern wheels
have raised letters on inside of plate. Standard is the only wrought manufacturer who shows the day of month the wheel was
manufactured. Do not confuse brand with class.
Enter Markings in Boxes as Shown Below
Class
Design
Mfgr.
Month
Year
Serial No.
Box 2930
Box 3134
Box 3536
Box 3738
Box 3940
Box 4148
Measure, as shown to the left, with a steel wheel
gauge or simplified wheel gauge. Check the
appropriate plate type in box on reverse.
*ABC Rail after July 1987.
Trademark Southern not used after August 1,
1980.
When wheel plates are marked as above, enter SO
for ABEX (Southern) under manufacturer.
C
J
-
8
8
S
O
U T H E R N
0
9
7 5 1 1 5
0
9
-
7
8
9
0
C
WHEEL MARKINGS, 1978 AND EARLIER
SERIAL
NUMBER
DESIGN
MONTH
YEAR
MFGR.
CLASS
J
3
6
1
2
7
8
C
W
B
1
3
3 7 3 1
SERIAL
NUMBER
DESIGN
MONTH
YEAR
MFGR.
CLASS
PLATE MARKING (ABEX)*
HUB STAMPING
8
-
2
0
-
7
8
0
9
7 5 1 1 5
C
S
O
U
T
H
E
R
N
C
J
-8
8
MONTH
YEAR
MFGR.
CLASS
O6
94
CW 62247 B
J36
MONTH
YEAR
MFGR. SERIAL
NUMBER
CLASS
DESIGN
0
6
9
4
C
W
62247
B
J
3
6
RIM STAMPING
HUB STAMPING
6
2 2 4 7 06 74 CW
B
MONTH
YEAR
MFGR.
CLASS
SERIAL
NUMBER
RIM STAMPING (LOCOMOTIVE ONLY)
1" MIN
333
TAPE SIZE
LOW STRESS HIGH STRESS
2/1/04
G-II112 2/1/04
SEGMENT 4.0 RP-633
Storage track arrangement for wheel and axle assemblies having applied roller bearings
with housing end covers that rotate
Fig. 4.74
Differentiation between 7 12 and 7 14 bearing application
Rule 1.8.2.1
Fig. 4.75
56 "
4 "
56 "
56 "
4 "
11.063"
11.563"
7" 12"
7" 14"
NOTES:
1. A 7" 12" BEARING APPLICATION USES A BACKING RING FITTED ON THE DUST GUARD DIAMETER.
2. A 7" 14" BEARING APPLICATION USES A NONFITTED BACKING RING.
3. AXLE END CAPS ARE MARKED ARE MARKED 7" 12" AND 7" 14", BUT ARE INTERCHANGEABLE BETWEEN ASSEMBLIES.
THE BACKING RING DESIGN SHOULD THUS BE THE DETERMINING FACTOR FOR PROPER JOURNAL APPLICATION.
4. IMPORTANT: THE 7" 14" BEARING APPLICATION IS NOT AN APPROVED AAR STANDARD.
5. THE 7" 12" BEARING APPLICATION UTILIZES EITHER A ONE PIECE OR A TWO PIECE BACKING/WEAR RING,
DEPENDING UPON THE MANUFACTURER SUPPLYING THE BEARING.
2/1/04
2/1/04 G-II113
SEGMENT 4.0 RP-633
AAR Roller Bearing Hot Box and Shop Inspection Report
Paragraphs 2.5.4 and 3.1.3
Fig. 4.76
2/1/04
G-II114 2/1/04
SEGMENT 4.0 RP-633
AAR Roller Bearing Hot Box and Shop Inspection Report
Paragraphs 2.5.4 and 3.1.3
Part IInspection
Box 121 Self-explanatory
Box 2224 Bearing certificate per end cap or, if colored, locking plate
per Table 1
Box 3842 Shop marks found on locking plate
Box 43107 Information taken from bearing having hot box
Part IIMate Bearing Report
All legible dates and information should be retrieved from bearing having
hot box, then add mate bearing information.
Box 110112 Bearing certificate per end cap or, if colored, locking plate
per Table 1
Box 113149 Information taken from mate bearing parts
Part IIICauses
Box 150152 Initial cause
Box 153155 Actual cause of heat
Box 156 Indicate position if causes are cup, cone, or seal
Table 1
Colored Locking Plate Certificate
Numbers
Timken 01.1AA Orange
Brenco 05.05A Green
Hyatt 06.06A Blue
Fag 13 Red
Koyo 14 White
NTN 10A.l9 Purple
SKF 23 Yellow
Examples
Helpful Hints for Causes of Hot Boxes Initial Defect
Cause of
Heat
1. Either a loose cap screw, loose hacking ring, undersize journal, or worn cone face will
allow cones to revolve on the journal and possibly cause rollers to break or spall.
2. Heavily spalled or worn cone raceway or spalled or worn rollers will cause heavy dam-
age to seal lips. Grease will leak from the bearing and foreign matter will enter.
3. A journal with an upset end will stretch the cone bores, allowing the cone to break or
revolve on the journal.
4. Seal loose, cut, ruptured, or worn, or casing dented will allow grease to leak out of the
bearing and foreign matter to enter.
5. A bearing overheated externally will show signs of the seal rubber embrittled and the
grease hardened or the oil evaporated from the grease leaving the soap behind.
6. A defective adapter will cause an uneven load distribution on the bearing cone assem-
blies.
7. A cap screw too long or the cap screw hole defective with rust, partially closed, or hav-
ing faulty threads will prevent the end cap from seating properly against the outboard
seal wear ring. Therefore, insufficient clamp will be provided and the bearing will be-
come loose on the journal while in service.
Explanation of Initial Defect and Cause of Heat
The Cause of Heat is the detect that obviously caused the bearing to be reported hot.
This obvious defect may be the result of another defect called Initial Defect. Always try
to determine the Initial Defect. If the Initial Defect cannot be determined, list the same
cause code under both Cause of Heat and Initial Defect.
Part IVProbable Factors/Parties Contributing to Bearing Failure
The information used to trace contributing factors/parties can be found on locking plates,
internal cup markings, and/or by identifying the RR handling the equipment. One or more
categories may apply.
Example
Improper bench lateral combined with poor clamp/inspection techniques
C A 1 C N 4
C U 2 L U 1
J R 2 C N 4
S E 1 L U 1
B E 2 L U 1
A D 1 C U 2
C A 2 C N 4
R
157
E
158
6
159
B
160
M
161
4
162
Instructions for Completing Form MD-11
2/1/04
2/1/04 G-II115
SEGMENT 4.0 RP-633
Locking plate markings
Rule 1.8.5.2
Fig. 4.77
END CAP REPLACEMENT DATA:
EC = End Cap replaced and
1/94 = Month/Year End Cap replaced and
BNSQ = Company and Shop Identification Marks
of shop replacing end cap
MOUNTING SHOP:
QSXK = Company and Shop
Identification Marks of shop
mounting bearing (Required
only if bearing is new or if
mounting shop is different
from reconditioning shop)
EC
1/94
BNSQ
Q
S
X
K
R
R
B
X
M
6
/
8
8
NEW OR RECONDITIONED and
RECONDITIONING SHOP DATA:
N = NEW &
6/88 or F-88 = MONTH/YEAR
Manufactured
OR
R = Reconditioned &
6/88 = Mth/Yr Reconditioned &
RBXM = Company & Shop
Identification Marks of
Reconditioning Shop
2/1/04
G-II116 2/1/04
SEGMENT 4.0 RP-633
AAR Wheel Procurement Report
Paragraph 3.1.4
Fig. 4.78
Reporting Company ____________________ AAR WHEEL PROCUREMENT REPORT 19__
AAR FORM MD-002 REVISED 6/96
Please ll in the blank Manufacturing blocks with approved manufacturers .
Other approved Wrought Steel Manufacturers for the time period are: ABB British Wheelsets (England), Canadian Steel Wheel
(Canada), Mafersa (Brazil), Sumitomo (Japan), Lovere (Italy), Valdunes (France), Zelezarny A Dratovny (Czech Republic),
Construcciones y Auxiliar de Ferrocarriles (Spain), S.C., SMR, S.A. Rolling Stock Assemblies, (Romania), SCAW Metals
(South Africa).
Other approved Cast Steel Manufacturers for the time period are: Fundiciones De Hierro Y Acero (Mexico), Ministry of Rail-
ways (India)
AAR Wrought Steel Wheel Designation
Manufacturer Class A-28 E-28 A-30 J-33 M-33 P-33 H-36 J-36 B-38 E-40 C-42
Standard Steel A
B
C
Edgewater Steel Company A
B
C
A
B
C
A
B
C
A
B
C
AAR Cast Steel Wheel Design
Manufacturer Class CA-28 CE-28 CA-30 CJ-33 CM-33 CP-33 CH-36 CJ-36 CB-38 CE-40 CC-42
Grif n Wheel Company A
B
C
ABC Rail A
B
C
A
B
C
2/1/04
2/1/04 G-II117
SEGMENT 5.0 RP-634
5.0 GAUGESWHEEL AND AXLE SHOP
5.1 Working drawings of gauges are included in this chapter if not covered in previous chapters.
Also included are illustrations of the use of some gauges when usage is not covered elsewhere in
this manual.
5.2 Applicable limit wear gauges and Master gauges for the gauges shown in this manual are
listed in the AAR Manual of Standards and Recommended Practices, Section G. The exception is
the limit wear gauge shown in Fig. 5.13.
5.3 Listed below are gauges and the location of working drawings.
Gauge See...
1. Steel wheel gauge (machined) Fig. 5.1
2. Steel wheel gauge (stamped) Fig. 5.4
3. Simplified wheel gauge Fig. 5.5
4. Back-to-back mounting gauge for all steel wheels Fig. 5.6
5. Gauges for centering wheels on axles Fig. 5.7
6. Wheel defect, worn collar, and journal fillet gauge
(machined)
Fig. 5.8
7. Wheel defect, worn collar, and journal fillet gauge
(stamped)
Fig. 5.10
8. Pin-type gauge for cap screw holes Fig. 5.12
9. Limit wear gauge for standard wheel gauge, sim-
plified wheel gauge and wheel defect gauge
Fig. 5.13
10. Instructions for using limit wear gauge Figs. 5.14, 5.15, 5.16 and 5.17
11. Journal fillet gauge and roller bearing seat loca-
tion
Fig. 5.18
12. Wheel circumference gauge (tape) for steel
wheels27-in. to 38-in. diameters
Fig. 5.20
13. Wheel circumference gauge (tape) for steel
wheels38-in. to 52-in. diameters
Fig. 5.21
14. Diameters and circumferences corresponding to
tape sizes
Fig. 5.22
15. Gauge for correct machining of wide flange con-
tour
Fig. 5.23
16. Gauge for checking U dimensionfreight car
roller bearing axles
Fig. 5.24
17. Axle centering gauge Fig. 5.25
18. Gauge for checking axle journal lengths Fig. 5.26
19. Wheel back-to-back service limit gauge (typical) Fig. 5.27
2/1/04
G-II118 2/1/04
SEGMENT 5.0 RP-634
Steel wheel gauge (machined)
(Working drawing)
Paragraphs 2.4.2 and 5.3
Fig. 5.1
COUNTERSINK
GAGE BODY
N.F. & N.F. FINGER
1
32"
SPRING WASHER
"
"
3
32"
3
16"
MEASURING LINE
1
.
3
9
8
7
1
.
5
4
5
1
1
.
6
9
4
1
1
.
7
3
1
8
1
.
8
8
3
8
2
.
0
3
8
4
2
.
1
9
5
9
A
TOL.
.005
1
0
2
3
4
5
6
1

3
1
6"

R
1
8 "
3
16"
.007
.005
5
8
1
5
'
REAM
.250
.251
1
9
16"
R
25
32"
5
16"
R
1
5
16"
R
9
16" 7
8 "
9
16"
R
1
64"
1
16"
R
49
64"
3
16"
R
21
32"
A
A
R

S
T
E
E
L

W
H
E
E
L
G
A
G
E

1
3
8
0
1

3
1
6"
C
L
3
8 "
30
1
64"
HARDEN AND GROUND ON
ALL GAGING SURFACES.
RUST PROOF FINISH.
A
0 AT 6 1.375
0 AT 5 1.3125
0 AT 4 1.250
0 AT 3 1.1875
0 AT 2 1.1719
0 AT 1 1.1094
0 AT 0 1.0469
1 "
.
0
0
2

B
E
T
W
E
E
N

A
N
Y

T
W
O

P
O
I
N
T
S
3
.
1
3
0
3
.
1
2
0
2
.
3
7
8
2
.
3
7
6
1
.
9
2
1
1
.
9
1
9
.
4
5
6
.
4
5
8
.752
.748
0
6
5
4
3
2
1
0
F
R
T
S
C
R
A
P
10
16
20
24
28
32
40
44
48
25
32"
.
8
7
6
.
8
4
8
1
16"
1
16" 2.877
2.873
38 50'
" R
1
9 1
6
"
R
1
"
+
.
0
0
5
.
0
0
3

2
"
"
1
8 "
1
8 "
1
16"
1
8 "
1
8 "
1
16"
3
8 "
3
64"
1
8 "
1
16"
1
16"
60
60
2 "
"R
7
16"
R
"R
7
8 "
R
2.013
2.015
2
23
64"
3
11
16"
45
.
3
8
0
.
3
7
0
.
8
7
7
.
8
7
3
1
.
0
0
2
0
.
9
9
8
.248
.252
"
2
.
2
5
5
2
.
2
4
5
3
.
7
5
5
3
.
7
4
5

5

4
3
6
4 "
3
32"
10
0
8
6
4
2
NF
90
3
8
5
0
'
5
3
1
16"
5
64"
NUMERIALS
" LETTERS
.007
.005
TO BE CALIBRATED
AS FOLLOWS:
TOL .002 BETWEEN
ANY TWO POINTS
0 TO 2 .056
2 TO 3 .043
3 TO 4 .049
4 TO 5 .051
5 TO 6 .037
6 TO 7 .041
7 TO 8 .045
8 TO 9 .058
07
3
32"
3
64"
WF
8 16' 46"
3
0
3
3
' 1
4
"
2
0
4
6
8
10
5
64"
NUMERALS
" LETTERS
1
16"
TO BE CALIBRATED
AS FOLLOWS:
TOL .002 BETWEEN
ANY TWO POINTS
0 TO 2 .079
2 TO 3 .047
3 TO 4 .042
4 TO 5 .042
5 TO 6 .037
6 TO 7 .047
7 TO 8 .063
8 TO 9 .068
9 TO 10 .084
10 TO 11 .107
2/1/04
2/1/04 G-II119
SEGMENT 5.0 RP-634
(Working drawing)
Fig. 5.2
0
2
4
6
8
1
0
W
F
WIDE FLANGE
MARKINGS
(OPTIONAL)
8
12
16
20
24
28
32
36
40
44
48
7
8
3
4
F
R
T
S
C
R
A
P
20
1
0
1
1
1
2
2
21
19
18
17
0
2
4
6
8
9
NF
.251A
R1.3125
.251B
R.3125
R.5625
R.7656
.126
R1.562
R.1875
0
.157
.375
R.44
1.139
2.014
2.36
3.39
R.50
.188
R.50
R.50
1.562
.457
.719
.781
1.918
2.375
3.129
R.88
38.833
1.500
1.63
R.25
.063
.063
2.876
.125
TYP.
.0625
TYP.
2.543
.13
.047
.06
.13
.13
.750
5.125
.50
1.00
.34
.14
.19
.25
.14
.25 IN. LINE
.125 IN. LINE
MATERIALS:
RIVET & THUMB KNOB
303 STAINLESS STEEL
BODY & FINGER
HARDENED
STAINLESS STEEL RIVET
MANUFACTURE TOLERANCE: .005
RECERTIFICATION TOLERANCE .010
Finger Radii Centers
0.3125 (0.00, 0.00)
0.251A (0.00, 0.00)
0.251B (0.755726, 0.685488)
1.3125 (0.0536604, 0.999073)
0.7656 (0.29881, 0.573978)
1.562 (0.00, 0.00)
0.126 (0.00, 1.49899)
0.5625 (0.0332779, 20.874367)
0.1875 (1.24331, 0.610423)
2/1/04
G-II120 2/1/04
SEGMENT 5.0 RP-634
(Working drawing)
Fig. 5.3
WIDE FLANGE MARKING
(OPTIONAL)
PROVIDE RELIEF
WHEN MARKED
FOR WIDE FLANGE
MANUFACTURE TOLERANCE: .005
RECERTIFICATION TOLERANCE .010
0
2
4
6
8
9
20
1
0
21
19
18
17
0
A
1.434
1.581
1.730
1.882
2.045
2.203
STAINLESS STEEL
THUMB KNOB
BLACK SPRING
WASHER
0
2
4
6
20
1
0
21
19
18
17
C
B
0
0
2
4
6
8
9
A
0 AT 22 1.375
0 AT 21 1.313
0 AT 20 1.250
0 AT 19 1.188
0 AT 18 1.125
0 AT 17 1.063
AT B
0 1.264
2 1.210
3 1.168
4 1.120
5 1.070
6 1.034
7 0.995
8 0.951
9 0.894
AT C
0 1.483
2 1.408
3 1.364
4 1.323
5 1.283
6 1.248
7 1.203
8 1.142
9 1.077
10 0.997
11 0.896
2/1/04
2/1/04 G-II121
SEGMENT 5.0 RP-634
Steel wheel gauge (stamped)
(Working drawing)
Fig. 5.4
NOTE: "STEEL WHEEL GAUGE1976" TO BE SUITABLY MARKED ON BACK SIDE OF GAUGE IN APPROXIMATELY
1
8 "
LETTERS
1.562
58
.007
.005
45
5
16"
R
1
5
16"
3
16"
R
1 "
5
16"
9
16"
7
8 "
9
16"
R
1
64"
0 TO 2 .056
2 TO 3 .043
3 TO 4 .049
4 TO 5 .051
5 TO 6 .037
6 TO 7 .041
7 TO 8 .045
8 TO 9 .058
TO BE CALIBRATED
AS FOLLOWS:
TOL = .002 BETWEEN ANY
TWO POINTS
9
0
8
6
4
2
5
64"
NUMERALS
.007
.005
" LETTERS
90
38 50'
53
NF
THUMB KNOB " DIAMETER
3
8 "
GAGE BODY
N.F. FINGER
SPRING WASHER
"
"
3
16"
0
F
R
T
S
C
R
A
P
0
1.267
1.270
3
11
16"
2
1
64"
"
45
3
8 "

2

"

2
.
3
7
5
2.875
.
7
5
1
.
7
5
3
1
.
4
9
8
1
.
5
0
0
38 50'
1
.
5
6
2
1
.
5
6
7
" R
" R
" R
1
16"
1
16"
" R
.
8
7
5

R
7 1
6
"

R

2
.
5
0
0

3
.
7
5
0
1
16"
60
1
16"
60
12
16
20
24
28
32
36
40
44
48
.
4
4
2
.
4
2
4
.
8
7
2
.
8
7
8
.047*
1
8 "
1
8 "
1
8 "
1
16"
3
8 "
.750"

5

5
8
"

2

2
9
6
4
"
"
*WEAR LIMIT FOR THIS DIMENSION
ONLY IS 0.037-IN.
MATERIAL: .093" STAINLESS STEEL FOR BODY OF GAUGE AND .050 STAINLESS STEEL OF SUITABLE HARDNESS FOR GAUGE
FINGER. TOLERANCES FOR DECIMAL DIMENSIONS ARE TO BE .005" AND FRACTIONAL DIMENSIONS ARE TO
BE
1
64"
UNLESS OTHERWISED SPECIFIED. REMOVE BURRS AND SHARP EDGES.
2/1/04
G-II122 2/1/04
SEGMENT 5.0 RP-634
Simplified wheel gauge
(for checking high flange, thin rim, and groved tread)
(Working drawing)
Paragraph 5.3
Fig. 5.5
MATERIAL: .093 STAINLESS STEEL. UNLESS OTHERWISE STATED ALL TOLERANCES ARE .010" . REMOVE
BURRS AND SHARP EDGES.
3
11
16"
1 "
" R
" R
1
16"
1
16"
25
32"
2
3
8 "
" R
" R
7
16"
R
7
8 "
R
2
7
8 "
" HOLE
STENCIL
SIMPLIFIED
WHEEL GAUGE
5
5
8 "
1
.
0
0
0
"
.
9
9
5
"
.
8
7
5
"
.
8
7
0
"
.
7
5
0
"
.
7
4
5
"
1
.
5
0
5
"
1
.
5
0
0
"
2 "
19
32"
"
7
8 "
1"
1"
"
1
8 "
1
16"
(FOR GROOVED TREAD MEASUREMENT)
*WEAR LIMIT FOR THIS DIMENSION ONLY IS 0.105-IN.
1
8 "
*
2/1/04
2/1/04 G-II123
SEGMENT 5.0 RP-634
Back-to-back mounting gauge for all steel wheels
(Working drawing)
Paragraph 5.3
Fig. 5.6
3
8 "

3
8 "
9
1"
8
ASSEMBLY WHEEL MOUNTING GAGE
PAINT WITH BLACK ENAMEL EXCEPT
CALIBRATION ROD & SURFACES COVERED
WITH HARD SURFACE METAL
HARDEN TIP
WITH ANY HARD
SURFACE METAL
GAGE TIP
FINISH ALL OVER
"- 20 N.C. THDS
TUBING
20 H.C. THDS
R
CALIBRATIONS DIVIDED INTO
1
16"
AND
SCRIBED - NUMBERS
1
32"
HIGH
6
5
16"
O. H. STEEL
AAR SPECN. M-116
GRADE B
APPLY ANY HARD SURFACE
METAL TO THIS SURFACE ONLY
GUIDE
HOLE DIA. TO BE .001"
SMALLER THAN DIA. OF ROD
APPLY ANY HARD SURFACE
METAL TO THE SURFACE ONLY
"

D
I
A
.
1
5"
32 30 4"
8 "
2 "
HARDENTIP WITHANY
HARDSURFACE METAL
5 25 35 45 55 6
1 "
3 "
F
F
PRESS PIT
45 CHAMFER
5
3
8 "
9
5
8 "
3
16"
DIA. PIN - RIVETED
1"
2
5
8 "
30
1"
1 "
1
8 "
1
8 "
1
8 "
5
4
7
8 "
"
1
8 "
"
" R
"
"
47
5
8 "
39
64" 1
13
64"
5
5 1
1
17
64"
"
10 9
11
WELD TO WITH THUMB
SCREW SLOT 30 FROM
HORIZONTAL CENTER LINE
10 3
7
12
8
6
3
2
1
8 "
5
8 "
13
32"
13
16"
3
13
16"
3
8 "
7
32"
1
8 "
3
8 "
" R
2
6
PRESS CALIBRATION ROD
INTO DETAIL WITH THUMB
SCREW TAP HOLE 30" FROM
HORIZONTAL AS SHOWN C
L
3
7
8 "
DIA. HOLE
17
64"
"
"
3
16"
5
8 "
DIA
CALIBRATION ROD
C.R. STEEL
6
1
16"
1
32"
9
16"
7
16"
1
13
32"
1 "
5"
1
8 "
R
GUIDE BAR
4
1
8 "
R
MAKE FROM
1
1
8 "
O.D. TUBING
7
1
8 "
15
16"
15
32"
7
16"
R
"
5
8 " 5
32"
"R
"
1
8 "
R
"
"
" DIA.
THUMB SCREW 8
5
32"
BRACE
9
13
16"
Bill of Material
Material Description
Number
Required
Item
Number
Steel
Tubing, 5/8 in. I.D. 13/16 in. O.D. 47 5/8 in. long 1 1
Guide 1 2
Guide bar 1 3
Guide bar 1 4
Gauge tip 1 5
Calibration rod 1 6
Guide washer 1 7
Thumb screw 1 8
Brace 2 9
Gauge tip bar, 3/8 in. 3/8 in. square 6 in. long 1 10
Bronze Spring, 0.0725-in. diameter wire 19/32 in. O.D. 6 3/8 in. long 36 coils 1 11
Steel Std. washer, 1/4 in. 1 12
2/1/04
G-II124 2/1/04
SEGMENT 5.0 RP-634
Gauges for centering wheels on axles
(Working drawing)
Paragraph 5.3
Fig. 5.7
"
" SQUARE STEEL
5
16"
THUMB SCREW
1
3
8 "
48" 3
8 "
1"
"
1"
"
1 "
C
L
AXLE
METHOD OF APPLICATION
3 "
8"
2"
1
8 "
STEEL PLATE
ALL ANGLE IRONS
1" 1"
3
16"
3
5
8 "
1
5
8 "
ALL RIVETS
3
16"
DIAMETER
*
2
6

3
5
6
4
"
2
6

5
8
"

F
O
R

A
M
T
R
A
K

C
A
R
S

O
N
L
Y
8
7
8 "
6"
6"
ANGLE 27"
LONG
ANGLE 26" LONG
1"
32"
38"
"
6
1
8 "
3 " R
1 "
2
6

3
5
6
4
"
1
8 "
STEEL PLATE
1
8 "
TOOL STEEL PLATE
HARDEN AND TEMPERED
WELDED OR RIVETED CONSTRUCTION PERMISSIBLE
AXLE CENTERING GAUGE
GAUGE FOR LOCATING FIRST WHEEL
* This dimension is 26 5/8 in. for Amtrak passenger cars.
** Wear limit for this dimension only is 26 33/64 in. Manufacturing tolerance for this dimension is 0.015 in.
Unless otherwise specified, all other manufacturing tolerances are +1/8 in., 1/16 in.
2/1/04
2/1/04 G-II125
SEGMENT 5.0 RP-634
Gauge for centering wheels on axles (with brake discs)
AmtrakPassenger cars
(Working drawing)
Paragraph 5.3
1
1

"
3
5
8 "
1"
2 "
13
5
8 "
18
5
8 "
*
2
6

5
8
"

2
4

5
8
"
13
5
8 "
3
5
8 "
34 " R
1"
2 "
INTERSECTS AT
CENTER LINE
1
5

"
1
3
16"
"
3
5
8 "
"
"
"
"
DRILL "
COUNTERSINK FOR
" " FLAT HEAD
MACHINE SCREW
"
BEVEL 45
"
DRILL
13
64"
THEN TAP
28 THDS/IN.
1 "
2 "
29"
36 "
FRAMESTAINLESS STEEL
FINGERHARDEN STEEL
FINGER
C
L
* Wear limit for this dimension only is 26 19/32 in. Manufacturing tolerance for this dimension is 0.015 in.
Unless otherwise specified, all other manufacturing tolerances are +1/8 in., 1/16 in.
2/1/04
G-II126 2/1/04
SEGMENT 5.0 RP-634
Wheel defect, worn collar, and journal fillet gauge (machined)
(Working drawing)
Fig. 5.8
3
32"
45
1
16"
.877
.873
1.002
.998
1.370
1.380
1.630
1.620
2.380
2.370
3.380
3.370
3.880
3.870
3
16"
R
3
32"
G G
G
G
G
45
15
16"
"
5
8 "
5
8 "
.248
.252
3
16"
LONG SCRIBE LINE
BOTH SIDES OF GAUGE
EQUAL SPACES
3
8 "
"
"
" R
1
8 "
R
R
.3175
.3075 STAMP SIZES OF
SLOTS ON EACH
SIDE OF GAUGE
"R
5
8 "
.255
.250
G
G
G
G
G
1 "
9
16"
R
1
7
32"
"R
.9365
.9385
5.127
5.123
1.0615
1.0635
5
8 "
2
15
16"
7
8 "
G
.255
.250
1
1
16"
1
8 "
R
.380
.370
R
2

"
.876
.874
R
3
8 "
REAM
1
64"
45 CHAMFER
GAUGE NUMBER 34401
MATERIAL: ASTM A-576, GRADE 1020
HARDEN AND GROUND ON ALL GAUGING SURFACES, CHROME-PLATED FINISH
5
16"
2/1/04
2/1/04 G-II127
SEGMENT 5.0 RP-634
Wheel defect, worn collar, and journal fillet gauge (machined)
(Working drawing)
Fig. 5.9
.500 .005 TYPICAL
.250 .005 TYPICAL
R
5
16
R
R
.063
.125
2
3
8
.781

9
16
R
1
1
64
1
1
7
8
1
8
1
8
.125
2.876
R
3
8
3
32
R
7
8
2
1
.875 .005
R
35
64
27
32
5
8
5
8
R
1
8
5
B
A
R.015
UNLESS OTHERWISE SPECIFIED
MANUFACTURE TOLERANCES : .010
MATERIAL:
STAINLESS STEEL 304
THICKNESS:
3
32
BOXED DIMENSIONS ARE MINIMUM
CHARACTERISTICS TO BE VERIFIED
FOR RECERTIFICATION.
RECERTIFICATION TOLERANCES .015"
4
7
64
1
8
2
1
2
2 1
1
2
1
1
2
0
COMBINED
WHEEL GAGE
3
4 7
8
1
1
4
1
1
8
1
R
7
16
1
5
1
6
KNOTCH DETAIL
0 (A=
3
16
, B=)
(A=
1
8
, B=
1
8
)
(A=
1
8
, B=
3
16
)
(A=
1
8
, B=
1
8
)
1 (A=
3
16
, B=)
1 (A=
1
8
, B=
1
8
)
1 (A=
1
8
, B=
3
16
)
1 (A=
1
8
, B=
1
8
)
2 (A=
3
16
, B=)
2 (A=
1
8
, B=
1
8
)
2 (A=
1
8
, B=
3
16
)
.125 .005
1.500 .005
.750 .005
.875 .005
1.250 .005
1.125 .005
1.000 .005
1.000 .005
1.000 .005
.938 .005
2.500 .005
50.173
R
2/1/04
G-II128 2/1/04
SEGMENT 5.0 RP-634
Wheel defect, worn collar, and journal fillet gauge (stamped)
(Working drawing)
Fig. 5.10
GAUGE NUMBER 34401A
MATERIAL: 0.093 STAINLESS STEEL.
UNLESS OTHERWISE STATED, ALL TOLERANCES ARE 0.010".
NOTE: THIS GAUGE CAN BE USED FOR
7
8 "
OR LESS FLANGE ON LOCOMOTIVE WHEELS.
45
.874
.876
3
16"
R
3
32"
15
16"
"
5
8 "
5
8 "
3
16"
LONG SCRIBE LINE
BOTH SIDES OF GAUGE
EQUAL SPACES
3
8 "
"
"
" R
1
8 "
R
STAMP SIZES OF
SLOTS ON EACH
SIDE OF GAUGE
"R
5
8 "
1 "
9
16"
R
1
7
32"
"R
.936
.938
5.130
5.120
5
8 "

7
8 "
R
2
15
16"
1
8 "
R
2

"
3
8 "
DIA

7
8 "
3
8 "

7
8 "
2"
3
8 "
R
1
5
8 "
1"
1"
1 "
2 "
3 "
"
5
16"
5
16"
R
2/1/04
2/1/04 G-II129
SEGMENT 5.0 RP-634
Wheel defect, worn collar, and journal fillet gauge (stamped)
(Working drawing)
Fig. 5.11
.500 .005 TYPICAL
.250 .005 TYPICAL
R
5
16
R
R
.063
.125
2
3
8
.781

9
16
R
1
1
64
1
1
7
8
1
8
1
8
.125
2.876
R
3
8
3
32
R
7
8
2
1
.875 .005
R
35
64
27
32
5
8
5
8
R
1
8
5
B
A
R.015
UNLESS OTHERWISE SPECIFIED
MANUFACTURE TOLERANCES : .010
MATERIAL:
STAINLESS STEEL 304
THICKNESS:
3
32
4
7
64
1
8
2
1
2
2 1
1
2
1
1
2
0
COMBINED
WHEEL GAGE
3
4 7
8
1
1
4
1
1
8
1
R
7
16
1
5
1
6
KNOTCH DETAIL
0 (A=
3
16
, B=)
(A=
1
8
, B=
1
8
)
(A=
1
8
, B=
3
16
)
(A=
1
8
, B=
1
8
)
1 (A=
3
16
, B=)
1 (A=
1
8
, B=
1
8
)
1 (A=
1
8
, B=
3
16
)
1 (A=
1
8
, B=
1
8
)
2 (A=
3
16
, B=)
2 (A=
1
8
, B=
1
8
)
2 (A=
1
8
, B=
3
16
)
.125 .005
1.500 .005
.750 .005
.875 .005
1.250 .005
1.125 .005
1.000 .005
1.000 .005
1.000 .005
.938 .005
2.500 .005
50.173
R
2/1/04
G-II130 2/1/04
SEGMENT 5.0 RP-634
Pin-type gauge for cap screw holes
(Working Drawing)
Rule 1.2.6 and Paragraph 5.3
Fig. 5.12
E
+

.
0
0
0
"

.
0
0
5
"
D
I
A
1
32"
R MAX
G
"
7
8 "
"

D
I
A
R
E
F
G
GRIND AT ASSEMBLY TO PROVIDE
APPROXIMATELY 0.0002" PRESS
FIT IN PIN HOLDER
A
120
A
120
DIA A
DIA B
C
+

.
0
0
1
"

.
0
0
0
"
1 "
DIA D
SECTION A A
5
8 "
5
8 "
1
8 "
R OR
1
8 "
45 CHAMFER
1
8 "
R
" DIA
2"
G
1
16"
R MAX
1
8 "
R
DRILL THREE INSPECTION HOLES
LOCATED IN LINE WITH PIN HOLES
MATERIAL: ASTM A-576, GRADE 1045 OR EQUIVALENT.
PARTS TO BE HARDEN AND SURFACES MARKED
WITH A G ARE TO BE GROUND. BREAK SHARP
CORNERS. TOLERANCES ON ALL DIMENSIONS TO
BE
1
64"
UNLESS OTHERWISE SPECIFIED.
THREE HOLES 0.5000" NOMINAL DIAMETER FOR PRESS FIT WITH PINS.
HOLES EQUALLY SPACED WITHIN 0.001" OF TRUE
POSITION IN ANT DIRECTION.
Freight Car Axles
Class Size, in. A B C D E
D 5 1/2 10 3.5000 6 3/16 5.195 2 3/8 .740
E 6 11 3.8750 6 11/16 5.695 2 5/8 .850
F
a/
6 1/2 12 4.2500 7 3/16 6.195 2 7/8 .955
G 7 12 4.6250 8 7.008 3 1/2 1.080
K
a/
6 1/2 9 4.2500 7 3/16 6.195 2 7/8 .955
Amtrak Passenger Car Axles
D 5 1/2 10 3.0000 6 1/2 5.507 1 7/8 .636
E 6 11 3.5000 7 6.007 2 3/8 .749
F 6 1/2 12 3.8750 7 1/2 6.507 2 5/8 .749
a/
Class F and Class K may use the same
gauge.
2/1/04
2/1/04 G-II131
SEGMENT 5.0 RP-634
Limit wear gauge for standard wheel gauge, simplified wheel gauge and wheel defect gauge
(Working drawing)
Paragraph 5.3
Fig. 5.13
3"
1.263
1.261
1
.
4
8
4
1
.
4
8
9
.
9
5
1
.
9
4
6
4 "
"
"
1 " HIGH
MUST NOT SEAT
O FINGER
READING
5
8 "
"
1
8 "
1
8 "
3
8 "
DIAMETER
7
16"
15
16"
NO GO
7
8 "
NO GO
0.890
0.885
THIS SIDE OF GAUGE TO BE STAMPED AS
SHOWN ON GAUGE.
OTHER SIDE OF GAUGE TO BE STAMPED:
LIMIT WEAR GAUGE FOR:
SIMPLIFIED WHEEL GAUGE
STEEL WHEEL GAUGE
WHEEL DEFECT GAUGE34401A
MATERIAL: 0.093 STAINLESS STEEL
REMOVE BURRS AND SHARP EDGES.
2/1/04
G-II132 2/1/04
SEGMENT 5.0 RP-634
Use of limit wear gauge (Fig. 5.13) for checking simplified wheel gauge, 1 1/2-in.-high flange condemning limit
Paragraph 5.3
Fig. 5.14
O FINGER
READING
15
16"
NO GO
7
8 "
NO GO
SIMPLIFIED
WHEEL GAUGE
WHEN CHECKING WEAR LIMITS,
BE CERTAIN BACK SIDE OF WEAR
GAUGE IS HELD FIRMLY AGAINST
LEG OF WHEEL GAUGE.
IF LIMIT WEAR GAUGE SEATS HERE,
THEN POINT OF WHELL GAUGE HAS
EXCESSIVE WEAR.
1
7
8 "
1 " HIGH
MUST NOT SEAT
2/1/04
2/1/04 G-II133
SEGMENT 5.0 RP-634
Use of limit wear gauge (Fig. 5.13) for checking wheel defect gauge, 7/8-in. flange condemning limits
Paragraph 5.3
Fig. 5.15
Use of limit wear gauge (Fig. 5.13) for checking wheel defect gauge, 15/16-in. flange condemning limits
Paragraph 5.3
Fig. 5.16
O

F
I
N
G
E
R
R
E
A
D
I
N
G
1
5
1
6
"

N
O

G
O
7
8
"

N
O

G
O
1

"

H
I
G
H
M
U
S
T

N
O
T

S
E
A
T
1
5
1
6
"

7
8
"
IF
7
8 "
NO-GO LEG OF LIMIT WEAR GAUGE
CAN BE INSERTED IN WHEEL DEFECT
GAUGE AT THIS POINT, THEN GAUGE HAS
EXCESSIVE WEAR.
O FINGER
READING
15
16"
NO GO
7
8 "
NO GO
1 " HIGH
MUST NOT SEAT
1
5
1
6
"

7
8
"
IF
15
16"
NO-GO LEG OF LIMIT WEAR GAUGE
CAN BE INSERTED IN WHEEL DEFECT
GAUGE AT THIS POINT, THEN GAUGE HAS
EXCESSIVE WEAR.
2/1/04
G-II134 2/1/04
SEGMENT 5.0 RP-634
Use of limit wear gauge (Fig. 5.13) for checking steel wheel gauge for 1 1/2-in.-high flange limits and finger gauge
readings
Paragraph 5.3
Fig. 5.17
6
5
4
3
2
1
0
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
1
1
2
2
2
1
2
3
O FINGER
READING
15
16"
NO GO
7
8 "
NO GO
1 " HIGH
MUST NOT SEAT
9
0
8
6
4
2
IF READING HERE IS PAST O,
THEN END OF FINGER HAS
EXCESSIVE WEAR.
IF LIMIT WEAR GAUGE SEATS HERE,
THEN POINT OF WHEEL GAUGE HAS
EXCESSIVE WEAR.
WHEN CHECKING WEAR LIMITS, BACK
SIDE OF WEAR GAUGE MUST BE HELD
FIRMLY AGAINST LEG OF WHEEL GAUGE
AND FINGER MUST BE IN PLACE AGAINST
GAUGE AT ARROW.
2/1/04
2/1/04 G-II135
SEGMENT 5.0 RP-634
Journal fillet gauge and roller bearing seat location
(Working drawing)
Rules 1.2.4 and 1.2.7.4 and Paragraph 5.3
Fig. 5.18
A
STENCIL AND SCRIBE LINES ON BOTH GAGE SIDES AS SHOWN
CRITICAL AREA
BEARING SEAT MUST BE
WITHIN TOLERANCE
CRITICAL AREA
BEARING SEAT MUST BE
WITHIN TOLERANCE
A
B
C
D
E
6 11
*1.5"R +0.000
0.005
1 "
2 "
1 "
1
16"
BEARING SEAT AREA
METHOD OF USING GAGE FOR LOCATING BEARING SEAT AREAS
AREA WHERE UPSET ENDS OCCUR
METHOD OF USING GAGE WHEN REWORKING UPSET
GAGE GAGE
MATERIAL 1/4-in. STEEL
Note: When reclaiming journals by plating, plating may extend into the base of the journal radius. Wear tolerance for this dimension only is +0.00 in.,
1/64 in.
Manufacturing tolerance for dimensions A, B, C, D, and E are 1/32 in. All other dimensions are 1/16 in.
Dimensions (in.)
Journal A B C D E
Class Size Freight Axles
D 5 1/2 10 2 5/8 4 57/64 6 8 21/32 19/32
E 6 11 2 7/8 5 13/64 6 9/16 9 5/16 43/64
F 6 1/2 12 2 15/16 5 45/64 7 1/16 10 3/8 43/64
G 7 12 2 3/8 5 5/16 6 1/2 9 13/16 1/2
K 6 1/2 9 1 53/64 4 19/32 5 8 5/16 43/64
Amtrak Axles
D 5 1/2 10 1 1/2 4 9/16 5 1/8 8 9/16 19/32
6 11 2 5 1/16 5 5/8 9 1/16 5/8
6 1/2 12 2 3/8 5 5/16 6 1/2 9 13/16 45/64
2/1/04
G-II136 2/1/04
SEGMENT 5.0 RP-634
Axle plating area
Rule 1.2.7.9
Fig. 5.19
Notes:
1. Repairs to be in accordance with the AAR Manual of Standards and Recommended Practices, Specification M-967latest
revision, except as noted below.
2. The length of the repair on the dust guard shall not exceed 0.375 in., except as shown.
3. Repaired dust guards shall not be roll burnished.
U
.375
PLATING FEATHERED OUT IN THIS
AREA. NO PLATING BEYOND BASE
OF RADIUS.
THICKNESS AS REQUIRED
(0.002-IN. MAXIMUM)
PLATING AREA
DUST GUARD DIAMETER AS
PER MSRP-G, Part II, FIG. 4.1.
2/1/04
2/1/04 G-II137
SEGMENT 5.0 RP-634
Wheel circumference gauge (tape) for steel wheels27-in. to 38-in. diameters
(Working drawing)
(See Fig. 5.22 for diameters and circumferences corresponding to tape sizes)
Paragraph 5.3
Fig. 5.20
Note: The scale on the wheel tape can have a tolerance of .005 between any two points on the scale with no accumulative variation. Linear dimensions
shown represent measurements of actual circumference of the wheel and not straight length of the tape. Graduations to be spaced
1
8 "
apart with tape
laid flat.
1
1
"
2
4

"
1
"
5
0
4
.
1
8
0
8
4
.
1
8
0
6
.
2
8
3
4
"
1
2
5
.
6
8
0
3
0
"

D
I
A
.

W
H
E
E
L
3
3
"

D
I
A
.

W
H
E
E
L
3
6
"

D
I
A
.

W
H
E
E
L
3
8
"

D
I
A
.

W
H
E
E
L
9
4
.
4
4
3
9
.
4
2
5
9
.
4
2
5
1
5
0
1
5
5
1
6
0
1
6
5
1
7
0
2
2
5
2
3
0
2
3
5
2
4
0
2
4
5
2
7
5
2
8
0
2
8
5
2
9
0
2
9
5
3
0
0
T
O

B
E

O
N

C
A
S
T
I
N
G
1

1

4

1

4
R
.
8
0
8
5
9
0
8
0
8
5
9
0
2
"
1
"
3
0
"
3
7

"
7
8
"
3
8
"
3
1
6
"
7
1
6
"
3
1
6
"
2
4

"
"
"
"
R
I
V
E
T

H
O
L
E
S
5
3
2
"
2
4

"
1
3
2
"
5
8
"
9
1
6
"
"
2
7
1 6 "
2
9
1 6 "
1
1
1 6 "
"
"
1
1
6
"
"
3
1
6
"
"
R
I
V
E
T
S
5
3
2
"
7
1
6
"
R
7
1
6
"
R
7
8
"
7
1
6
"
R
"
R
1
5
8
"
1
1
6
"
R
1
8
"
"
5
3
2
"
5
3
2
"
5
3
2
"
1
1

"

R
R
I
V
E
T
S
5
3
2
"
1
5
8
"
"
1
1
6
"
1
8
"
3
8
"
1
3
8
"
5
3
2
"
1
1
6
"
1
5
8
"
2
9
3
2
"
6

"
7
1
6
"
3
8
"
1
1
6
"
7
8
"
5
3
2
"
R
I
V
E
T
S
5
3
2
"
7
1
6
"
7
1
6
"
3
8
"
3
8
"
2

7
1
6
"
7
1
6
"
R
1
1
6
"
R
7
8
"
"
R
R
5
3
2
"
1
8
"
7
1
6
"
3
8
"
1
8
"
5
3
2
"
"
1
8
"
5
3
2
"
2/1/04
G-II138 2/1/04
SEGMENT 5.0 RP-634
Wheel circumference gauge (tape) for steel wheels38-in. to 52-in. diameters
(Working drawing)
(See Fig. 5.22 for diameters and circumferences corresponding to tape sizes)
Paragraph 5.3
Fig. 5.21
1
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6
.
6
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1
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2
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4
5
5
3
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3
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7
8
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3
8
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1
8
"
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"
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1
1
1
1
6 "
9
1
6 "
2
9
1
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1
9
1
6 "
R
I
V
E
T
S
5
8
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1
1
6 "
1
1
1
6 "7
8
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5
8
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7
8
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5
8
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3
8
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R
6

"
1
5
8
"
"
R
"
R
1
5
8
"
3
8
"
1
8
"
5
8
"
1
8
"
5
8
"
1
8
"
1
8
"
1
8
"
5
8
"
7
8
"
1
5
8
"
3
8 "
R
1
"
3
8
"
3
8
"
2/1/04
2/1/04 G-II139
SEGMENT 5.0 RP-634
Diameters and circumferences corresponding to tape sizes
Paragraph 5.3
Fig. 5.22
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
0 26 47 84
1 26 50 84 1/8
2 26 52 84 1/4
3 26 55 84 3/8
4 26 57 84 1/2
5 26 60 84 5/8
6 26 63 84 3/4
27 0 84 53/64
7 27 1 84 7/8
8 27 4 85
9 27 6 85 1/8
10 27 9 85 1/4
11 27 11 85 3/8
12 27 14 85 1/2
13 27 16 85 5/8
14 27 19 85 3/4
15 27 21 85 7/8
16 27 24 86
17 27 27 86 1/8
18 27 29 86 1/4
19 27 32 86 3/8
20 27 34 86 1/2
21 27 37 86 5/8
22 27 39 86 3/4
23 27 42 86 7/8
24 27 44 87
25 27 47 87 1/8
26 27 49 87 1/4
27 27 52 87 3/8
28 27 55 87 1/2
29 27 57 87 5/8
30 27 60 87 3/4
31 27 62 87 7/8
28 0 87 31/32
32 28 1 88
33 28 3 88 1/8
34 28 6 88 1/4
35 28 8 88 3/8
36 28 11 88 1/2
37 28 13 88 5/8
38 28 16 88 3/4
39 28 19 88 7/8
40 28 21 89
41 28 24 89 1/8
42 28 26 89 1/4
43 28 29 89 3/8
44 28 31 89 1/2
45 28 34 89 5/8
46 28 36 89 3/4
47 28 39 89 7/8
48 28 41 90
49 28 44 90 1/8
50 28 47 90 1/4
51 28 49 90 3/8
52 28 52 90 1/2
53 28 54 90 5/8
54 28 57 90 3/4
55 28 59 90 7/8
56 28 62 91
29 0 91 7/64
57 29 1 91 1/8
58 29 3 91 1/4
59 29 5 91 3/8
60 29 8 91 1/2
61 29 11 91 5/8
62 29 13 91 3/4
63 29 16 91 7/8
64 29 18 92
65 29 21 92 1/8
66 29 23 92 1/4
67 29 26 92 3/8
68 29 28 92 1/2
69 29 31 92 5/8
70 29 33 92 3/4
71 29 36 92 7/8
72 29 39 93
73 29 41 93 1/8
74 29 44 93 1/4
75 29 46 93 3/8
76 29 49 93 1/2
77 29 51 93 5/8
78 29 54 93 3/4
79 29 56 93 7/8
80 29 59 94
81 29 61 94 1/8
82 30 0 94 1/4
83 30 3 94 3/8
84 30 5 94 1/2
85 30 8 94 5/8
86 30 10 94 3/4
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
87 30 13 94 7/8
88 30 15 95
89 30 18 95 1/8
90 30 20 95 1/4
91 30 23 95 3/8
92 30 26 95 1/2
93 30 28 95 5/8
94 30 31 95 3/4
95 30 33 95 7/8
96 30 36 96
97 30 38 96 1/8
98 30 41 96 1/4
99 30 43 96 3/8
100 30 46 96 1/2
101 30 48 96 5/8
102 30 51 96 3/4
103 30 54 96 7/8
104 30 56 97
105 30 59 97 1/8
106 30 61 97 1/4
107 30 64 97 3/8
31 0 97 25/64
108 31 2 97 1/2
109 31 5 97 5/8
110 31 7 97 3/4
111 31 10 97 7/8
112 21 12 98
113 31 15 98 1/8
114 31 18 98 1/4
115 31 20 98 3/8
116 31 23 98 1/2
117 31 25 98 5/8
118 31 28 98 3/4
119 31 30 98 7/8
120 31 33 99
121 31 35 99 1/8
122 31 38 99 1/4
123 31 40 99 3/8
124 31 43 99 1/2
125 31 46 99 5/8
126 31 48 99 3/4
127 31 51 99 7/8
128 31 53 100
129 31 56 100 1/8
130 31 58 100 1/4
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
131 31 61 100 3/8
132 31 63 100 1/2
32 0 100 17/32
133 32 2 100 5/8
134 32 4 100 3/4
135 32 7 100 7/8
136 32 10 101
137 32 12 101 1/8
138 32 15 101 1/4
139 32 17 101 3/8
140 32 20 101 1/2
141 32 22 101 5/8
142 32 25 101 3/4
143 32 27 101 7/8
144 32 30 102
145 32 32 102 1/8
146 32 35 102 1/4
147 32 38 102 3/8
148 32 40 102 1/2
149 32 43 102 5/8
150 32 45 102 3/4
151 32 48 102 7/8
152 32 50 103
153 32 53 103 1/8
154 32 55 103 1/4
155 32 58 103 3/8
156 32 60 103 1/2
157 32 63 103 5/8
33 0 103 43/64
158 33 2 103 3/4
159 33 4 103 7/8
160 33 7 104
161 33 9 104 1/8
162 33 12 104 1/4
163 33 14 104 3/8
164 33 17 104 1/2
165 33 19 104 5/8
166 33 22 104 3/4
167 33 24 104 7/8
168 33 27 105
169 33 30 105 1/8
170 33 32 105 114
171 33 35 105 3/8
172 33 37 105 1/2
173 33 40 105 5/8
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
a/
Diameters are expressed to the nearest 1/64 corresponding to the exact circumference stated.
2/1/04
G-II140 2/1/04
SEGMENT 5.0 RP-634
Paragraph 5.3
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
174 33 42 105 3/4
175 33 45 105 7/8
176 33 47 106
177 33 50 106 1/8
178 33 53 106 1/4
179 33 55 106 3/8
180 33 58 106 1/2
181 33 60 106 5/8
182 33 63 106 3/4
34 0 106 13/16
183 34 1 106 7/8
184 34 4 107
185 34 6 107 1/8
186 34 9 107 1/4
187 34 11 107 3/8
188 34 14 107 1/2
189 34 17 107 5/8
190 34 19 107 3/4
191 34 22 107 7/8
192 34 24 108
193 34 27 108 1/8
194 34 29 108 1/4
195 34 32 108 3/8
196 34 34 108 1/2
197 34 37 108 5/8
198 34 39 108 3/4
199 34 42 108 7/8
200 34 45 109
201 34 47 109 1/8
202 34 50 109 1/4
203 34 52 109 3/8
204 34 55 109 1/2
205 34 57 109 5/8
206 34 60 109 3/4
207 34 62 109 7/8
35 0 109 61/64
208 35 1 110
209 35 3 110 1/8
210 35 6 110 1/4
211 35 9 110 3/8
212 35 11 110 1/2
213 35 14 110 5/8
214 35 16 110 3/4
215 35 19 110 7/8
216 35 21 111
217 35 24 111 1/8
218 35 26 111 1/4
219 35 29 111 3/8
220 35 31 111 1/2
221 35 34 111 5/8
222 35 37 111 3/4
223 35 39 111 7/8
224 35 42 112
225 35 44 112 1/8
226 35 47 112 1/4
227 35 49 112 3/8
228 35 52 112 1/2
229 35 54 112 5/8
230 35 57 112 3/4
231 35 59 112 7/8
232 35 62 113
36 0 113 3/32
233 36 1 113 1/8
234 36 3 113 1/4
235 36 6 113 3/8
236 36 8 113 1/2
237 36 11 113 5/8
238 36 13 113 3/4
239 36 16 113 7/8
240 36 18 114
241 36 21 114 1/8
242 36 23 114 1/4
243 36 26 114 3/8
244 36 29 114 1/2
245 36 31 114 5/8
246 36 34 114 3/4
247 36 36 114 7/8
248 36 39 115
249 36 41 115 1/8
250 36 44 115 1/4
251 36 46 115 3/8
252 36 49 115 1/2
253 36 51 115 5/8
254 36 54 115 3/4
255 36 57 115 7/8
256 36 59 116
257 36 62 116 1/8
37 0 116 15/64
258 37 2 116 1/4
259 37 3 116 3/8
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
260 37 5 116 1/2
261 37 8 116 5/8
262 37 10 116 3/4
263 37 13 116 7/8
264 37 16 117
265 37 18 117 1/8
266 37 21 117 1/4
267 37 23 117 3/8
268 37 26 117 1/2
269 37 28 117 5/8
270 37 31 117 3/4
271 37 33 117 7/8
272 37 36 118
273 37 38 118 1/8
274 37 41 118 1/4
275 37 44 118 3/8
276 37 46 118 1/2
277 37 49 118 5/8
278 37 51 118 3/4
279 37 54 118 7/8
280 37 56 119
281 37 59 119 1/8
282 37 61 119 1/4
283 37 64 119 3/8
38 0 119 3/8
284 38 2 119 1/2
285 38 5 119 5/8
286 38 8 119 3/4
287 38 10 119 7/8
288 38 13 120
289 38 15 120 1/8
290 38 18 120 1/4
291 38 20 120 3/8
292 38 23 120 1/2
293 38 25 120 5/8
294 38 28 120 3/4
295 38 30 120 7/8
296 38 33 121
297 38 36 121 1/8
298 38 38 121 1/4
299 38 41 121 3/8
300 38 43 121 1/2
301 38 46 121 5/8
302 38 48 121 3/4
303 38 51 121 7/8
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
304 38 53 122
305 38 56 122 1/8
306 38 58 122 1/4
307 38 61 122 3/8
308 38 64 122 1/2
39 0 122 33/64
309 39 2 122 5/8
310 39 5 122 3/4
311 39 7 122 7/8
312 39 10 123
313 39 12 123 1/8
314 39 15 123 1/4
315 39 17 123 3/8
316 39 20 123 1/2
317 39 22 123 5/8
318 39 25 123 3/4
319 39 28 123 7/8
320 39 30 124
321 39 33 124 1/8
322 39 35 124 1/4
323 39 38 124 3/8
324 39 40 124 1/2
325 39 43 124 5/8
326 39 45 124 3/4
327 39 48 124 7/8
328 39 50 125
329 39 53 125 1/8
330 39 56 125 1/4
331 39 58 125 3/8
332 39 61 125 1/2
333 39 63 125 5/8
40 0 125 21/32
334 40 2 125 3/4
335 40 4 125 7/8
336 40 7 126
337 40 9 126 1/8
338 40 12 126 1/4
339 40 14 126 3/8
340 40 17 126 1/2
341 40 20 126 5/8
342 40 22 126 3/4
343 40 25 126 7/8
344 40 27 127
345 40 30 127 1/8
346 40 32 127 1/4
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
a/
2/1/04
2/1/04 G-II141
SEGMENT 5.0 RP-634
Paragraph 5.3
Fig. 5.22 C (Continued)
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
347 40 35 127 3/8
348 40 37 127 1/2
349 40 40 127 5/8
350 40 43 127 3/4
351 40 45 127 7/8
352 40 48 128
353 40 50 128 1/8
354 40 53 128 1/4
355 40 55 128 3/8
356 40 58 128 1/2
357 40 60 128 5/8
358 40 63 128 3/4
41 0 128 13/16
359 41 1 128 7/8
360 41 4 129
361 41 7 129 1/8
362 41 9 129 1/4
363 41 12 129 3/8
364 41 14 129 112
365 41 17 129 5/8
366 41 19 129 3/4
367 41 22 129 7/8
368 41 24 130
369 41 27 130 1/8
370 41 29 130 1/4
371 41 32 130 3/8
372 41 35 130 112
373 41 37 130 5/8
374 41 40 130 3/4
375 41 42 130 7/8
376 41 45 131
377 41 47 131 1/8
378 41 50 131 1/4
379 41 52 131 3/8
380 41 55 131 1/2
381 41 57 131 5/8
382 41 60 131 3/4
383 41 63 131 7/8
42 0 131 61/64
384 42 1 132
385 42 4 132 1/8
386 42 6 132 1/4
387 42 9 132 3/8
388 42 11 132 1/2
389 42 14 132 5/8
390 42 16 132 3/4
391 42 19 132 7/8
392 42 21 133
393 42 24 133 1/8
394 42 27 133 1/4
395 42 29 133 3/8
396 42 32 133 1/2
397 42 34 133 5/8
398 42 37 133 3/4
399 42 39 133 7/8
400 42 42 134
401 42 44 134 1/8
402 42 47 134 1/4
403 42 49 134 3/8
404 42 52 134 1/2
405 42 55 134 5/8
406 42 57 134 3/4
407 42 60 134 7/8
408 42 62 135
43 0 135 3/32
409 43 1 135 1/8
410 43 3 135 1/4
411 43 6 135 3/8
412 43 8 135 1/2
413 43 11 135 5/8
414 43 13 135 3/4
415 43 16 135 7/8
416 43 19 136
417 43 21 136 1/8
418 43 24 136 1/4
419 43 26 136 3/8
420 43 29 136 1/2
421 43 31 136 5/8
422 43 34 136 3/4
423 43 36 136 7/8
424 43 39 137
425 43 41 137 1/8
426 43 44 137 1/4
427 43 47 137 3/8
428 43 49 137 1/2
429 43 52 137 5/8
388 42 54 137 3/8
431 43 57 137 7/8
432 43 59 138
433 43 62 138 1/8
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
44 0 138 15/64
434 44 0 138 1/4
435 44 3 138 3/8
436 44 5 138 1/2
437 44 8 138 5/8
438 44 11 138 3/4
439 44 13 138 7/8
440 44 16 139
441 44 18 139 1/8
442 44 21 139 1/4
443 44 23 139 3/8
444 44 26 139 1/2
445 44 28 139 5/8
446 44 31 139 3/4
447 44 34 139 7/8
448 44 36 140
449 44 39 140 1/8
450 44 41 140 1/4
451 44 44 140 3/8
452 44 46 140 1/2
453 44 49 140 5/8
454 44 51 140 3/4
455 44 54 140 7/8
456 44 56 141
457 44 59 141 1/8
458 44 62 141 1/4
... 45 0 141 3/8
459 45 0 141 3/8
460 45 3 141 1/2
461 45 5 141 5/8
462 45 8 141 3/4
463 45 10 141 7/8
464 45 13 142
465 45 15 142 1/8
466 45 18 142 1/4
467 45 20 142 3/8
468 45 23 142 1/2
469 45 26 142 5/8
470 45 28 142 3/4
471 45 31 142 7/8
472 45 33 143
473 45 38 143 1/8
474 45 38 143 1/4
475 45 41 143 3/8
476 45 43 143 1/2
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
477 45 46 143 5/8
478 45 48 143 3/4
479 45 51 143 7/8
480 45 54 144
481 45 56 144 1/8
482 45 59 144 1/4
483 45 61 144 3/8
484 45 64 144 1/2
46 0 1443 3/64
485 46 2 144 5/8
486 46 5 144 3/4
487 46 7 144 7/8
488 46 10 145
489 46 12 145 1/8
490 46 15 145 1/4
491 46 18 145 3/8
492 46 20 145 1/2
493 46 23 145 5/8
494 46 25 145 3/4
495 46 28 145 7/8
496 46 30 146
497 46 33 146 1/8
498 46 35 146 1/4
499 46 38 146 3/8
500 46 40 146 1/2
501 46 43 146 5/8
502 46 46 146 3/4
503 46 48 146 7/8
504 46 51 147
505 46 53 147 1/8
506 46 56 147 1/4
507 46 58 147 3/8
508 46 61 147 1/2
509 46 63 147 5/8
47 0 147 21/32
510 47 2 147 3/4
511 47 4 147 7/8
512 47 7 148
513 47 10 148 1/8
514 47 12 148 1/4
515 47 15 148 3/8
516 47 17 148 1/2
517 47 20 148 5/8
518 47 22 148 3/4
519 47 25 148 7/8
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
a/
2/1/04
G-II142 2/1/04
SEGMENT 5.0 RP-634
Paragraph 5.3
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
520 47 27 149
521 47 30 149 1/8
522 47 32 149 1/4
523 47 35 149 3/8
524 47 38 149 1/2
525 47 40 149 5/8
526 47 43 149 3/4
527 47 45 149 7/8
528 47 48 150
529 47 50 150 1/8
530 47 53 150 1/4
531 47 55 150 3/8
532 47 58 150 1/2
533 47 61 150 5/8
534 47 63 150 3/4
48 0 150 51/64
535 48 2 150 7/8
536 48 4 151
537 48 7 151 1/8
538 48 9 151 1/4
539 48 12 151 3/8
540 48 14 151 1/2
541 48 17 151 5/8
542 48 19 151 3/4
543 48 22 151 7/8
544 48 25 152
545 48 27 152 1/8
546 48 30 152 1/4
547 48 32 152 3/8
548 48 35 152 1/2
549 48 37 152 5/8
550 48 40 152 3/4
551 48 42 152 7/8
552 48 45 153
553 48 47 153 1/8
554 48 50 153 1/4
555 48 53 153 3/8
556 48 55 153 1/2
557 48 58 153 5/8
558 48 60 153 3/4
559 48 63 153 7/8
49 0 153 15/16
560 49 1 154
561 49 4 154 1/8
562 49 6 154 1/4
563 49 9 154 3/8
564 49 11 154 1/2
565 49 14 154 5/8
566 49 17 154 3/4
567 49 19 154 7/8
568 49 22 155
569 49 24 155 1/8
570 49 27 155 1/4
571 49 29 155 3/8
572 49 32 155 1/2
573 49 34 155 5/8
574 49 37 155 3/4
575 49 39 155 7/8
576 49 42 156
577 49 45 156 1/8
578 49 47 156 1/4
579 49 50 156 3/8
580 49 52 156 1/2
581 49 55 156 5/8
582 49 57 156 3/4
583 49 60 156 7/8
584 49 62 157
50 0 157 5/64
585 50 1 157 1/8
586 50 3 157 1/4
587 50 6 157 3/8
588 50 9 157 1/2
589 50 11 157 5/8
590 50 14 157 3/4
591 50 16 157 7/8
592 50 19 158
593 50 21 158 1/8
594 50 24 158 1/4
595 50 26 158 3/8
596 50 29 158 1/2
597 50 31 158 5/8
598 50 34 158 3/4
599 50 37 158 7/8
600 50 39 159
601 50 42 159 1/8
602 50 44 159 1/4
603 50 47 159 3/8
604 50 49 159 1/2
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
605 50 52 159 5/8
606 50 54 159 3/4
607 50 57 159 7/8
608 50 59 160
609 50 62 160 1/8
51 0 160 7/32
610 51 1 160 1/4
611 51 3 160 3/8
612 51 6 160 1/2
613 51 8 160 5/8
614 51 11 160 3/4
615 51 13 160 7/8
616 51 16 161
617 51 18 161 1/8
618 51 21 161 1/4
619 51 24 161 3/8
620 51 26 161 1/2
621 51 29 161 5/8
622 51 31 161 3/4
623 51 34 161 7/8
624 51 36 162
625 51 39 162 1/8
626 51 41 162 1/4
627 51 44 162 3/8
628 51 46 162 1/2
629 51 49 162 5/8
630 51 52 162 3/4
631 51 54 162 7/8
632 51 57 163
633 51 59 163 1/8
634 51 62 163 1/4
52 0 163 23/64
635 52 0 163 3/8
636 52 3 163 1/2
637 52 5 163 5/8
638 52 8 163 3/4
639 52 10 163 7/8
640 52 13 164
641 52 16 164 1/8
642 52 18 164 1/4
643 52 21 164 3/8
644 52 23 164 1/2
645 52 26 164 5/8
646 52 28 164 3/4
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
647 52 31 164 7/8
648 52 33 165
649 52 36 165 1/8
650 52 38 165 1/4
651 52 41 165 3/8
652 52 44 165 1/2
653 52 46 165 5/8
654 52 49 165 3/4
655 52 51 165 7/8
656 52 54 166
657 52 56 166 1/8
658 52 59 166 1/4
659 52 61 166 3/8
660 52 64 166 1/2
53 0 166 1/2
Tape
No.
Diameter
Circum.
(in.)
in. 64ths
a/
2/1/04
2/1/04 G-II143
SEGMENT 5.0 RP-634
Gauge for correct machining of wide flange contour
(see Fig. 4.36)
Paragraph 5.3
Fig. 5.23
ETCH ON GAGE
1 IN 20 NOMINAL TREAD
& FLANGE GAGE FOR
AAR-1B WIDE FLANGE WHEEL
6.5000"
1.3750"
.0010"
.7857"
.0010"
.5893"
.0010"
R.3750"
BASE LINE
TAPER 1:20
(REF.)
R.0625" R 0.0625" .7500"
4
.
0
0
0
0
"
2
.
0
0
0
0
"
1
.
0
0
0
0
"
.
0
0
1
0
"
R
.
6
2
5
0
"
.
0
0
1
0
"
R.6875"
.0010"
R1.5000"
.0010"
R.3750"
.0010"
R.5625"
.0010"
.
6
2
5
0
"
.
0
0
1
0
"
.
2
3
0
6
"
.
0
0
1
0
"
.
5
2
4
3
"
.
0
0
1
0
"
2.0064"
.0010"
2.5721"
.0010"
GAUGING POINT
R2.6250"
.0010"
+
+
+
+ +
+
+ +
+
F
E
D B F
C
E
1
2
3
4
5
6
7
8
9
A
+
R 1.5000"
+0.0010
- 0.0010
R 0.5625"
+0.0010
- 0.0010
NOTES:
1. HANGING HOLE(S) OPTIONAL.
2. ALL DIMENSIONS ARE NOMINAL.
3. MINIMUM 0.120" STEEL WITH MINIMUM 55 RC HARDNESS.
4. UNLESS NOTED, ALL OTHER TOLERANCES ARE 0.0250.
Center of Radii Relative to Baseline
and Back of Flange
Point X (in.) Y (in.)
A 2.5721 .5235
B .7857 .3750
C .7857 .3132
D 1.0128 .5279
E 1.9553 .6325
F 2.4367 1.4369
Intersection Points Relative to Baseline
and Back of Flange
Point X (in.) Y (in.)
1 .0000 .0000
2 .2274 .6560
3 .7857 1.0000
4 1.2849 .7860
5 1.3750 .6250
6 1.4120 .4869
7 1.6665 .1498
8 2.0064 .0000
9 2.3618 .0612
2/1/04
G-II144 2/1/04
SEGMENT 5.0 RP-634
Gauge for checking U dimensionfreight car roller bearing axles
(Working drawing)
Rule 1.2.4 and Paragraph 5.3
Fig. 5.24
SHOP LIMIT
NEW AXLE MIN
A
WELD WELD " PIPE
SHOP LIMITS
NEW AXLE MINIMUM
1
8 "
1
16"
2
3
8 "
21
32"
1
32"
FOR AMTRAK
PASSENGER CARS
A
1"
4"
3
16"
STENCIL
3
16"
STEEL
Journal Size
(in.)
Dimension A .010 (in.)
Freight Cars Amtrak Cars
5 1/2 10 66.063 67.250
6 11 66.188 67.250
6 1/2 12 66.188 67.125
7 12 67.183
6 1/2 9 69.356
2/1/04
2/1/04 G-II145
SEGMENT 5.0 RP-634
Axle centering gauge
(Working Drawing)
Paragraph 5.3
Fig. 5.25
1
16"
THICK STEEL
HARDENED
LATHE CENTER
60
2"
60
1.750" MAX
1.500" MIN
1.375" MAX
1112
78910
1.125 MIN
4"
STENCIL NUMBERS
APPLY GRADUATIONS
AT DIMENSIONS SHOWN.
MANUFACTURING TOLERANCE FOR
THIS DIMENSION IS ONLY 5 MINUTES.
WEAR LIMIT FOR THIS DIMENSION IS 30 MINUTES.
Notes:
1. Depth of counterbore in rough axle shall be increased from that shown to compensate for stock allowed to face axle. When
secondhand axles are recentered, diameter and depth may be increased sufficiently to produce accurate 60 degree center.
2. All other manufacturing tolerances are 1/32 in.
2/1/04
G-II146 2/1/04
SEGMENT 5.0 RP-634
Gauge for checking axle journal lengths
Paragraph 5.3
Fig. 5.26
"

D
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A
.
1

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5

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3

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5
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D
.
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3
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4
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7
.
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2
8

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7
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0
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4

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.
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5
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6
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1
1

3
1
6
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7
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1
2
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G

1
1

7
8
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6

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2
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F

1
1

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6
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6
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E

1
0

3
1
6
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5

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0
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9

7
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8

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8
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B
4
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+
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0
0
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0
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1
8
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C
E
N
T
E
R
I
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B
O
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T
M
A
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L
.
-
C
O
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1
5
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6
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A
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E
,

A
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L
E

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I
L
L
E
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A
.
"
1
"
R
+
.
0
0
0
.
0
0
5
2/1/04
2/1/04 G-II147
SEGMENT 5.0 RP-634
Wheel back-to-back service limit gauge (typical)
Rules 1.5.3 and 1.7.9 and Paragraph 5.3
Fig. 5.27
53.1875 .0100
52.938 .010
2
GAUGING PADDLE
1
8 "
THICK
HARDENED
HANDLE
ALUMINUM
1 (2 REQ'D)
REFERNCE PADDLE
STANLESS STEEL 17-7
1
8 "
THICK
HARDENED
SUPPORT ALUMINUM
1
ALIGNING PLATE
3
16"
THICK
HARDENED
ALIGNING PLATE
3
16"
THICK
HARDENED
5
7
8 " 4
2/1/04
G-II148 2/1/04
APPENDIX A
APPENDIX A
APPROVED MATERIALS
1.0 APPROVED RUST PREVENTIVES USED AS SEALING COMPOUNDS
(Apply per Rule 1.8.2.6)
Tectyl 506 EH-WDAshland Petroleum Company
Texacoat 1044 Texaco Company
Rust Veto 342.1E.F. Houghton & Co.
CN-471-Perolin-Bird Archer, Ltd.
Keystone Sealing CompoundPennwalt, Inc.
Keycote 601Pennwalt, Inc.
Tectyl 517Ashland Petroleum Company
RP-103Diversey Corporation
2.0 AAR-APPROVED WHEEL MOUNTING LUBRICANTS/COMPOUNDS
(Apply per Rule 1.4.3)
RMI LB-0749 Custom Product and Service
WM-10 Wheel Mounting CompoundMuscle Products Corp.
2/1/04
2/1/04 G-II149
APPENDIX B
APPENDIX B
REVISED PAGE DATES
Shown below are the current dates applicable to each page of Section G-II of the AAR Manual of Standards and Rec-
ommended Practices. The printed page date is shown in either the lower left or lower right-hand corner of the page. In
the event a new specification, standard, or recommended practice does not include an effective date, the printed page
date will constitute the effective date.
Page Numbers
Front Reverse
Cover2/1/04 Copyright2/1/04
G-IIi2/1/04 G-IIii2/1/04
G-IIiii2/1/04 G-IIiv2/1/04
G-IIv2/1/04 G-IIvi2/1/04
G-IIvii2/1/04 G-IIviii2/1/04
G-IIix2/1/04 G-IIx2/1/04
G-IIxi2/1/04 G-IIxii2/1/04
G-II12/1/04 G-II22/1/04
G-II32/1/04 G-II42/1/04
G-II52/1/04 G-II62/1/04
G-II72/1/04 G-II82/1/04
G-II92/1/04 G-II102/1/04
G-II112/1/04 G-II122/1/04
G-II132/1/04 G-II142/1/04
G-II152/1/04 G-II162/1/04
G-II172/1/04 G-II182/1/04
G-II192/1/04 G-II202/1/04
G-II212/1/04 G-II222/1/04
G-II232/1/04 G-II242/1/04
G-II252/1/04 G-II262/1/04
G-II272/1/04 G-II282/1/04
G-II292/1/04 G-II302/1/04
G-II312/1/04 G-II322/1/04
G-II332/1/04 G-II342/1/04
G-II352/1/04 G-II362/1/04
G-II372/1/04 G-II382/1/04
G-II392/1/04 G-II402/1/04
G-II412/1/04 G-II422/1/04
G-II432/1/04 G-II442/1/04
G-II452/1/04 G-II462/1/04
G-II472/1/04 G-II482/1/04
G-II492/1/04 G-II502/1/04
G-II512/1/04 G-II522/1/04
G-II532/1/04 G-II542/1/04
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Page Numbers
Front Reverse
2/1/04
G-II150 2/1/04
APPENDIX B
2/1/04

Norma AAR Rodas Eixos

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